WO2011015859A1 - Method - Google Patents

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Publication number
WO2011015859A1
WO2011015859A1 PCT/GB2010/051271 GB2010051271W WO2011015859A1 WO 2011015859 A1 WO2011015859 A1 WO 2011015859A1 GB 2010051271 W GB2010051271 W GB 2010051271W WO 2011015859 A1 WO2011015859 A1 WO 2011015859A1
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WO
WIPO (PCT)
Prior art keywords
mixed metal
less
compound
slurry
metal compound
Prior art date
Application number
PCT/GB2010/051271
Other languages
French (fr)
Inventor
Richard Jonathan Applewhite
James David Morrison
Maurice Sydney Newton
Nigel Peter Rhodes
Christopher John Rickard
Original Assignee
Ineos Healthcare Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Ineos Healthcare Limited filed Critical Ineos Healthcare Limited
Priority to CN201910277263.XA priority Critical patent/CN110357165B/en
Priority to JP2012523389A priority patent/JP5894073B2/en
Priority to EP19186506.2A priority patent/EP3611131A1/en
Priority to ES10739987T priority patent/ES2751325T3/en
Priority to US13/388,476 priority patent/US9314481B2/en
Priority to EP10739987.5A priority patent/EP2462062B1/en
Priority to DK10739987.5T priority patent/DK2462062T3/en
Priority to CN201080040879.2A priority patent/CN102498068B/en
Publication of WO2011015859A1 publication Critical patent/WO2011015859A1/en
Priority to US14/224,040 priority patent/US9066917B2/en
Priority to US15/133,206 priority patent/US20160296557A1/en

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    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61K—PREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
    • A61K33/00—Medicinal preparations containing inorganic active ingredients
    • A61K33/24—Heavy metals; Compounds thereof
    • A61K33/26—Iron; Compounds thereof
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61K—PREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
    • A61K33/00—Medicinal preparations containing inorganic active ingredients
    • A61K33/06—Aluminium, calcium or magnesium; Compounds thereof, e.g. clay
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61K—PREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
    • A61K33/00—Medicinal preparations containing inorganic active ingredients
    • A61K33/06—Aluminium, calcium or magnesium; Compounds thereof, e.g. clay
    • A61K33/10—Carbonates; Bicarbonates
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61K—PREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
    • A61K45/00—Medicinal preparations containing active ingredients not provided for in groups A61K31/00 - A61K41/00
    • A61K45/06—Mixtures of active ingredients without chemical characterisation, e.g. antiphlogistics and cardiaca
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61K—PREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
    • A61K6/00—Preparations for dentistry
    • A61K6/80—Preparations for artificial teeth, for filling teeth or for capping teeth
    • A61K6/84—Preparations for artificial teeth, for filling teeth or for capping teeth comprising metals or alloys
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61K—PREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
    • A61K9/00—Medicinal preparations characterised by special physical form
    • A61K9/14—Particulate form, e.g. powders, Processes for size reducing of pure drugs or the resulting products, Pure drug nanoparticles
    • A61K9/141—Intimate drug-carrier mixtures characterised by the carrier, e.g. ordered mixtures, adsorbates, solid solutions, eutectica, co-dried, co-solubilised, co-kneaded, co-milled, co-ground products, co-precipitates, co-evaporates, co-extrudates, co-melts; Drug nanoparticles with adsorbed surface modifiers
    • A61K9/143—Intimate drug-carrier mixtures characterised by the carrier, e.g. ordered mixtures, adsorbates, solid solutions, eutectica, co-dried, co-solubilised, co-kneaded, co-milled, co-ground products, co-precipitates, co-evaporates, co-extrudates, co-melts; Drug nanoparticles with adsorbed surface modifiers with inorganic compounds
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61K—PREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
    • A61K9/00—Medicinal preparations characterised by special physical form
    • A61K9/14—Particulate form, e.g. powders, Processes for size reducing of pure drugs or the resulting products, Pure drug nanoparticles
    • A61K9/16—Agglomerates; Granulates; Microbeadlets ; Microspheres; Pellets; Solid products obtained by spray drying, spray freeze drying, spray congealing,(multiple) emulsion solvent evaporation or extraction
    • A61K9/1605—Excipients; Inactive ingredients
    • A61K9/1611—Inorganic compounds
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61K—PREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
    • A61K9/00—Medicinal preparations characterised by special physical form
    • A61K9/14—Particulate form, e.g. powders, Processes for size reducing of pure drugs or the resulting products, Pure drug nanoparticles
    • A61K9/16—Agglomerates; Granulates; Microbeadlets ; Microspheres; Pellets; Solid products obtained by spray drying, spray freeze drying, spray congealing,(multiple) emulsion solvent evaporation or extraction
    • A61K9/1682—Processes
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61P—SPECIFIC THERAPEUTIC ACTIVITY OF CHEMICAL COMPOUNDS OR MEDICINAL PREPARATIONS
    • A61P3/00—Drugs for disorders of the metabolism
    • A61P3/12—Drugs for disorders of the metabolism for electrolyte homeostasis
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61P—SPECIFIC THERAPEUTIC ACTIVITY OF CHEMICAL COMPOUNDS OR MEDICINAL PREPARATIONS
    • A61P7/00—Drugs for disorders of the blood or the extracellular fluid
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B82—NANOTECHNOLOGY
    • B82Y—SPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES
    • B82Y30/00—Nanotechnology for materials or surface science, e.g. nanocomposites
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01G—COMPOUNDS CONTAINING METALS NOT COVERED BY SUBCLASSES C01D OR C01F
    • C01G49/00—Compounds of iron
    • C01G49/009—Compounds containing, besides iron, two or more other elements, with the exception of oxygen or hydrogen
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
    • C01P2002/00—Crystal-structural characteristics
    • C01P2002/20—Two-dimensional structures
    • C01P2002/22—Two-dimensional structures layered hydroxide-type, e.g. of the hydrotalcite-type
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
    • C01P2002/00—Crystal-structural characteristics
    • C01P2002/60—Compounds characterised by their crystallite size
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
    • C01P2002/00—Crystal-structural characteristics
    • C01P2002/70—Crystal-structural characteristics defined by measured X-ray, neutron or electron diffraction data
    • C01P2002/72—Crystal-structural characteristics defined by measured X-ray, neutron or electron diffraction data by d-values or two theta-values, e.g. as X-ray diagram
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
    • C01P2004/00—Particle morphology
    • C01P2004/51—Particles with a specific particle size distribution
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
    • C01P2004/00—Particle morphology
    • C01P2004/60—Particles characterised by their size
    • C01P2004/61—Micrometer sized, i.e. from 1-100 micrometer
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
    • C01P2004/00—Particle morphology
    • C01P2004/60—Particles characterised by their size
    • C01P2004/64—Nanometer sized, i.e. from 1-100 nanometer
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
    • C01P2006/00—Physical properties of inorganic compounds
    • C01P2006/11—Powder tap density
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
    • C01P2006/00—Physical properties of inorganic compounds
    • C01P2006/12—Surface area
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
    • C01P2006/00—Physical properties of inorganic compounds
    • C01P2006/14—Pore volume
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
    • C01P2006/00—Physical properties of inorganic compounds
    • C01P2006/80—Compositional purity
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
    • C01P2006/00—Physical properties of inorganic compounds
    • C01P2006/80—Compositional purity
    • C01P2006/82—Compositional purity water content

Definitions

  • the present invention relates to a method for producing mixed meta! compounds and to compounds prepared by these methods These compounds may have pharmaceutical activity, especially as phosphate binders
  • the present invention further relates to novel mixed metal compounds
  • the invention relates to pharmaceutical compositions containing the above compounds and to the pharmaceutical use of the compounds
  • Hyperphosphataemia is an electrolyte disturbance in which there is an abnormally elevated level of phosphate in biood Hyperphosphataemia is frequently seen in dialysis patients, as standard dialysis regimes are unable to remove the ingested phosphate load even with a low phosphate diet, and is associated with an increased risk of death and the development of vascular calcification
  • the presence of hyperphosphataemia leads to hypocalcaemia, secondary hyperparathyroidism, reduced 1 ,25 Vit D3 and progressive metabolic bone disease Hyperphosphataemia is ultimately responsible for the increase in vascular calcification, but recent studies have also suggested that the process may additionally be influenced by 1 ,25 Vit D3 and an elevated caiciurn-phosphate product Patients who have chronically uncontrolled hyperphosphataemia develop progressively extensive soft tissue calcifications due to the deposit of Calcium/phosphate product into skin, joints, tendons, ligaments.
  • aluminium salts included aluminium salts
  • use of aluminium salts was found to result in further toxic complications due to aluminium accumulation, e.g reduction in haemoglobin production, impairment in natural repair and production of bone and possible impairment of neurological/cognitive function Renal bone disease, osteomalacia and dementia are the most significant toxicities related to the absorption of aluminium.
  • Other aluminium compounds such as microcrystalline aluminium oxide hydroxide (boehmite) and certain hydrotaicttes were proposed for this use, such as disclosed in Ookubo et al, Journal Pharmaceutical Sciences (November 1992), 81 (1 1),
  • Calcium carbonate or calcium acetate are used as phosphate binders
  • these suffer from the drawback that they tend to promote hypocalcaemia through the absorption of high amounts of ingested calcium and are linked to accelerated cardiovascular calcification which can cause serious side effects. Consequently, frequent monitoring of serum calcium levels is required during therapy with calcium-based phosphate binders
  • the National Kidney Foundation Kidney Disease Quality Outcomes Initiative suggests the limited use of calcium based salts (Clinical Practice Guidelines for Bone Metabolism and Disease in Chronic Kidney Disease, Guide 5, pg 1 pt 5 5) Recent efforts, therefore, have focused on the development of phosphate binders free of calcium.
  • Seveiamer hydrochloride is a water-absorbing, non- absorbed hydrogel-cross-iinked polyallylamine hydrochloride but because of its structure also binds certain fat-soluble vitamins and bile acids and is therefore reported in V Autissier et al, Journal of Pharmaceutical Sciences, VoI 96, No 10, October 2007 to require large doses to be effective because it has a higher propensity for the bound phosphate to be displaced by these competing anions.
  • Lanthanum carbonate is a phosphate binder which has been shown to be as effective as calcium carbonate with lower incidence of hypocalcaemia. Long-term administration of lanthanum, a rare earth element, continues to raise safety concerns with regards to the potential accumulation of a rare earth metal in body tissue which can be enhanced in renal failure - Tilman B Druke, Seminars in Dialysis, Volume 20, Issue 4 page 329-332 July/August 2007
  • WO-A-99/15189 discloses use of mixed metal compounds which are free from aluminium and which have a phosphate binding capacity of at least 30% by weight of the total weight of phosphate present, over a pH range of from 2-8.
  • LDH Layered Double Hydroxide
  • mixed metal compound it is meant that the atomic structure of the compound includes the cations of at least two different metals distributed uniformly throughout its structure.
  • the term mixed metal compound does not include mixtures of crystals of two salts, where each crystal type only includes one metal cation.
  • Mixed metal compounds are typically the result of coprecipitation from solution of different single metal compounds in contrast to a simple solid physical mixture of two different single metal salts.
  • Mixed metal compounds as used herein include compounds of the same metal type but with the metal in two different valence states e g Fe(II) and Fe(III) as well as compounds containing more than two different metal types in one compound.
  • the mixed metal compound may also comprise amorphous (non-crystalline) material.
  • amorphous is meant either crystalline phases which have crystallite sizes below the detection limits of x-ray diffraction techniques, or crystalline phases which have some degree of ordering, but which do not exhibit a crystalline diffraction pattern and/or true amorphous materials which exhibit short range order, but no long-range order
  • mixed metal compound for attaining phosphate therapeutic effects (or other pharma functional use) depends on surface processes such as physisorption (ion-exchange) and chemisorption (formation of a chemical bond) which is atypical for a drug; the therapeutic activity of most drugs are based on organic compounds which are typically more soluble
  • MgAS mixed metal compounds which are manufactured in the aged form for medical applications such as antacids, do not address the problems of manufacture of unaged mixed metal compounds (on a larger scale), when the unaged form is required, for example to maintain therapeutic activity of phosphate binding Furthermore, when replacing Al for Fe we found that the mixed metal compound changes properties such as to becoming more difficult to wash and mill on a commercial scale
  • these methods describe lab-scale preparations only Furthermore, these materials are obtained via a process which includes an ageing step (Le a deliberate process of increasing crystal growth which is typically achieved by heating the reaction slurry over a prolonged period of time such as by a hydrothermal process).
  • an ageing step Le a deliberate process of increasing crystal growth which is typically achieved by heating the reaction slurry over a prolonged period of time such as by a hydrothermal process.
  • the compounds of the prior art also contain substantially more than one type of anion in the interlayer region.
  • the present invention provides a method of producing a mixed metal compound comprising
  • the present invention provides a method of producing a mixed metal compound comprising
  • the present invention provides a method of producing a mixed metal compound comprising
  • the present invention provides a mixed meta! compound comprising at least Mg 2+ and at least Fe 3+
  • the present invention provides a mixed metal compound comprising at least Mg 2+ and at least Fe 3+
  • the present invention provides a mixed metal compound comprising at least Mg 2+ and at least Fe 3+
  • the present invention provides a mixed metal compound comprising at least Mg 2+ and at least Fe 3+
  • the present invention provides a mixed metal compound comprising at least Mg 2+ and at least Fe 3+ ,
  • the molar ratio of Mg 2+ to Fe 3+ is 2 5.1 to 1 5: 1 ,
  • the mixed metal compound has an aluminium content of less than 10000 ppm, the average crystal size of the mixed metal compound is from 10 to 20 ⁇ m (100 to 2Q ⁇ A), and the d50 average particle size of the mixed metal compound is less than 300 ⁇ m
  • the present invention provides a mixed metal compound comprising at least Mg 2+ and at ieast Fe 3+ ,
  • the molar ratio of Mg 2+ to Fe 3+ is 2 5:1 to 1 5:1 ,
  • the mixed metal compound has an aluminium content of less than 10000 ppm, the average crystal size of the mixed metal compound is from 10 to 20nm (100 to 200A), and the water pore volume of the mixed metal compound is from 0.25 to 0 7 cm 3 /g of mixed metal compound !n one aspect the present invention provides a mixed metal compound comprising at ieast Mg 2+ and at least Fe 3+ ,
  • the molar ratio of Mg 2+ to Fe 3+ is 2 5:1 to 1 5: 1,
  • the mixed metal compound has an aluminium content of iess than 10000 ppm, the average crystal size of the mixed metal compound is from 10 to 20nm (100 to 200A), and the interiayer sulphate content of the compound is from 1.8 to 5 wt%
  • the present invention provides a mixed metal compound comprising at least Mg 2+ and at least Fe 3+ ,
  • the molar ratio of Mg 2+ to Fe 3+ is 2 5: 1 to 1 5:1 r the mixed metal compound has an aluminium content of less than 10000 ppm, the average crystal size of the mixed metal compound is from 10 to 20nm (100 to 200A), and the interlayer sulphate content of the compound is from 1 8 to 3 2 wt%.
  • the present invention provides a mixed metal compound comprising at least Mg 2+ and at ieast Fe 3+ ,
  • the molar ratio of Mg 2+ to Fe 3+ is 2 5:1 to 1 5-1 ,
  • the mixed metal compound has an aluminium content of less than 10000 ppm, the average crystal size of the mixed metal compound is less than 20nm (20 ⁇ A), and the interlayer sulphate content of the compound is from 1 8 to 5 wt%.
  • the present invention provides a mixed metal compound comprising at least Mg 2+ and at least Fe 3+ ,
  • the molar ratio of Mg 2+ to Fe 3+ is 2 5:1 to 1.5 1 ,
  • the mixed metal compound has an aluminium content of less than 10000 ppm, the average crystal size of the mixed metal compound is less than 20nm (200A) 1 and the interlayer sulphate content of the compound is from 1 8 to 3 2 wt%
  • the present invention provides a mixed metal compound comprising at least Mg 2+ and at least Fe 3+ ,
  • the molar ratio of Mg 2+ to Fe 3+ is 2 5:1 to 1 5 1,
  • the mixed metal compound has an aluminium content of less than 10000 ppm, the average crystal size of the mixed metal compound is less than 20 ⁇ m (200A), and the surface area is from 80 to 145m 2 per gram of compound,
  • the present invention provides a mixed metal compound comprising at least Mg 2+ and at least Fe 3+ ,
  • the molar ratio of Mg 2+ to Fe 3+ is 2 5-1 to 1.5:1 ,
  • the mixed metal compound has an aluminium content of less than 10000 ppm, the average crystal size of the mixed metal compound is from 10 to 20nm (100 to 20 ⁇ A), the surface area is from 40 to 80 m 2 per gram of compound.
  • the present invention provides a mixed metal compound as described herein for use as a medicament
  • the present invention provides a mixed metal compound as described herein for binding phosphate
  • the present invention provides a mixed metal compound as described herein for use in the treatment of hyperphosphataemia !n one aspect the present invention provides a pharmaceutical composition comprising a mixed metal compound as described herein and optionally one or more pharmaceutically acceptable adjuvants, excipients, diluents or carriers
  • the present method provides a process which may be operated on a large scale to provide for a pharmaceutical phosphate binding drug of consistent composition which is stable upon storage and can be easily formulated and/or packaged. Moreover, the present method provides for control of key properties such as average crystal size, particle size, surface area, other morphology parameters (such as pore volume) and degree of hydration - ail of which are important for such manufacture
  • A!-free mixed metal compounds containing Fe and Mg typically have a clay-like structure This presents limitations in view of the difficult filtration of such products which in turn affect the viability of a controlled process
  • the present method provides a process which allows for manufacture of a consistent 'Al- free 1 mixed metal compounds suitable for use in final product formulations (e g tablet formulations etc)
  • the present process provides a method for a consistent manufacture of pharmaceutical-grade 'Al-free' mixed metal compounds with consistent particle- and crystallite-size
  • the present invention provides a mixed metal compound comprising at least Mg 2+ and at ieast Fe 3+ , wherein the molar ratio of Mg 2+ to Fe 3+ is 2 5i to 1 5:1 , the mixed metal compound has an aluminium content of less than 10000 ppm, the average crystal size of the mixed metal compound is from 10 to 20nm (100 to 200A) 1 and the interiayer sulphate content of the compound is from 1 8 to 5 wt%
  • the combination of process parameters of the present method provides for the preparation of mixed metal compounds which have controlled sulphate (SO 4 ) levels in the interiayer region.
  • Soluble SO 4 in the form of Na 2 SO 4 salt can be readily removed by washing whereas the interiayer sulphate cannot be removed by washing with water
  • the interiayer sulphate could be reduced without necessarily increasing the filtration and wash times by reslurrying the dried compound in a solution containing carbonate enabling ion-exchange; however, this meant an additional reaction, isolation and drying step and generally lead to a decrease in phosphate binding
  • this route would result in a longer overall time to manufacture. This route to control interlayer sulphate is therefore less preferred.
  • the interlayer sulphate may be reduced by washing or reslurrying the filtercake after isolation with a solution containing carbonate instead of water Again this would lead to an additional process step and is less preferred
  • the present invention may provide a process for preparing a mixed metal compound having a lead content of less than 1 ppm and/or a chromium content of less than 30 ppm and/or a total heavy metai content of less than 10 ppm and/or a sodium content expressed as Na 2 O of less than 0,5 wt%. in one aspect the mixed metal compound has a total heavy meta!
  • the present invention may provide a process for preparing a mixed metal compound having a total heavy metal content of less than 15 ppm, a !ead content less than 10 ppm, a chromium level less than 35 ppm and a sodium content (expressed as Na 2 O) of less than 1 wt%,
  • Heavy metals content as referred to herein are the group consisting of As, Cd, Pb, Hg, Sb, Mo and Cu
  • reference to total heavy metal content will be understood to mean the combined content of As, Cd, Pb, Hg, Sb, Mo and Cu.
  • WO99/15189 teaches the preparation of a slurry at pH above 10 using a 5 mole Na 2 CO 3 : 12 mole NaOH ratio which equates to an excess of 4 mole NazCOa than required to complete the reaction equation:
  • the present method is a co-precipitation process
  • Such processes encourage the formation of different crystalline phases in addition to the hydrotalcite phase
  • the present method provides for the preparation of mixed metal compounds which contain less of (or are substantially free of) any other crystalline phases as determined by the absence of XRD diffraction lines except those attributed to a hydrotalcite phase.
  • the hydrotalcite phase had the following diffraction X- ray diffraction analysis.
  • peaks marked * are the eight most intense peaks typically seen in the unaged samples The remaining five peaks are only resolved in more crystalline samples, typically as a result of ageing
  • the present invention provides a mixed metal compound comprising at least Mg 2+ and at least Fe 3+ , wherein the molar ratio of Mg 2+ to Fe 3+ is 1 5:1 to 2 5:1 , the mixed metal compound has an aluminium content of less than 10000 ppm, the average crystal size of the mixed metal compound is from 10 to 20nm (100 to 200 A) 1 and the d50 average particle size of the mixed metal compound is less than 300 ⁇ m
  • an average crystal size of the mixed metal compound of less than 20nm (200A) and high surface area (80-145 m 2 /g) can be manufactured using a process comprising a short residence drying step such that the resultant material has both small average crystal size and high surface area but also importantly has a higher phosphate binding capacity as well as a lower magnesium release when compared at similar d50 average particle size to that of the low surface area (40-80 m 2 /g) materia!; even when the material is not milled further.
  • the requirement for no milling has the advantage of reduced processing steps.
  • a further advantage is that such material can be suitable for tabletting processes without the need for wet granulation
  • a further advantage is that material manufactured via the short residence route may be exposed to temperatures above 150 0 C because the residence time (less than 5 minutes) of the product in the dryer is generally too short to enable any decomposition of the compound.
  • the mixed metal compound having an average crystal size of from 10 to 20nm (100 to 200A) and surface area 40-80 m 2 /g has the benefit of good stability in particular phosphate binding, on storage
  • This product has the additional benefit of providing a smaller tablet size (i e less than 500 mm 3 for 500 mg compound) thereby improving tablet pill burden; a prevalent issue within the treatment of rena! patients.
  • the product of 10 to 20nm (100 to 2O ⁇ A) average crystal size and 40-80 m 2 /g surface area has the additional benefit of providing a smaller tablet size (i.e. less than 500 mm 3 for 500 mg compound) thereby improving tablet pill burden; a prevalent issues within the treatment of renal patients. Furthermore a higher density materia! is more suitable for the manufacture by wet granulation of compact tablets.
  • the product is dried such that it has 80 wt% to 99 wt% dry solid content, preferably 85 wt% to 99 wt%
  • the present invention provides a mixed metal compound comprising at least Mg 2+ and at least Fe 3+ , wherein the molar ratio of Mg 2+ to Fe 3+ is 1.5: 1 to 2 5.1 , the mixed metal compound has an aluminium content of less than 10000 ppm, the average crystal size of the mixed metal compound is from 10 to 20nm (100 to 200A), and the water pore volume of the mixed metal compound is from 0.3 to 0 65 cm 3 /g of mixed metal compound
  • this low pore volume compound has the advantage of good phosphate binding that is essentially unchanged upon storage over periods of up to years, making it viable as a pharmaceutically active material It may be expected typically that significantly higher pore volumes would be required to attain such stability
  • water pore volume' refers to the pore volume as determined in accordance with Test Method 15
  • the present invention provides a method of producing a mixed rnetai compound comprising
  • step (a) a Mg 2+ salt and a Fe 3+ salt are combined with Na 2 CO 3 and NaOH to produce a slurry, wherein the pH of the slurry is maintained at from 9 5 to 10 5
  • the pH of the slurry is maintained at from 9 5 to less than 10 1
  • the pH of the slurry is maintained at from 9 5 to less than 10.
  • the pH of the slurry is maintained at from 9 5 to Sess than 9.8, Preferably the pH of the slurry is maintained at from 9 6 to 9 9 More preferably the pH of the slurry is maintained at approximately 9 8
  • a Mg 2+ salt and a Fe 3+ salt are combined with Na 2 CO 3 and NaOH to produce a slurry, wherein the Na 2 CO 3 is provided at an excess from 2 O to less than 4 O moles, preferably at an excess from 2 7 to less than 4 O moles, preferably at an excess from 2.7 to less than 3 2 moles, preferably at an excess from 2.7 to less than 3.0 moles More preferably the Na 2 CO 3 is maintained at an excess of approximately 2.7 moles
  • step (a) a Mg 2+ salt and a Fe 3* salt are combined with Na 2 CO 3 and NaOH to produce a slurry, wherein the slurry is maintained to a temperature between 15 and 30 0 C
  • step (iii) wherein the pH of the slurry is maintained at from 9 5 to no greater than 10 ⁇ 1 , and wherein the Na 2 CO 3 is provided at an excess of greater than 1 O to no greater than 2.7 moles than is required to complete the reaction; or (iv) wherein the pH of the slurry is maintained at from 9.5 to 10.5, and wherein the Na 2 CO 3 is provided at an excess of from greater than 1.0 to no greater than 2 O moles than is required to complete the reaction, or (v) wherein the pH of the slurry is maintained at from greater than 9 5 to no greater than 1 1 , and wherein the Na 2 CO 3 is provided at an excess of from 0.0 to no greater than 1 O moles than is required to complete the reaction.
  • step (a) a Mg 2+ salt and a Fe 3+ salt are combined with Na 2 CO 3 and NaOH to produce a slurry, wherein the slurry is maintained to a temperature between 15 and 30 0 C
  • step (a) a Mg 2+ salt and a Fe 3+ salt are combined with Na 2 CO 3 and NaOH to produce a slurry, wherein the slurry is maintained to a temperature from 30 to 60 °C
  • step (iii) wherein the pH of the slurry is maintained at from greater than 9 5 to less than 10, and wherein the Na 2 CO 3 is provided at an excess of greater than 0 to less than 4 moles than is required to complete the reaction
  • step (a) a Mg 2+ salt and a Fe 3+ salt are combined with Na 2 CO 3 and NaOH to produce a slurry, wherein the slurry is maintained to a temperature from 30 to 65 °C
  • step (b) wherein the pH of the slurry is maintained at from 9 5 to less than 10, and wherein the Na 2 CO 3 is provided at an excess of greater than 0 to less than 4 moles than is required to complete the reaction
  • the slurry in step (b) the slurry is subjected to mixing under conditions providing a power per unit volume of 0 03 to 1 6kW/m 3
  • the slurry in step (b) the slurry is subjected to mixing under conditions providing a power per unit volume of 0.03 to 0.5kW/m 3
  • step (b) the slurry is subjected to mixing under conditions providing a power per unit volume of 0.05 to 0 5kW/m 3
  • the slurry in step (b) the slurry is controlled to a d50 particle size distribution (psd) of at least 40 ⁇ m.
  • the slurry is controlled to a d50 psd of greater than 40 ⁇ m, Preferably, the slurry is controlled to a d50 psd of at least 50 ⁇ m Preferably, the slurry is controlled to a d50 psd of at least 60 ⁇ m. More preferably, the slurry is controiled to a d50 psd of at least 70 ⁇ m Preferably, the slurry is controlled to a d50 psd of greater than 70 ⁇ m.
  • the d50 psd of the slurry is as measured in accordance with Test Method 9 herein
  • the term 'particle size distribution' refers to the d50 or average particle size distribution as determined in accordance with Test Method 24 D50 refers to the 50th percentile of that Test Method
  • step (b) the slurry is controlled to a d50 psd of at least 40 ⁇ m after the addition of the reactants and after an initial hold time of 30 minutes to attain the optimum particle size distribution,
  • the slurry is controiled to a d50 psd of at least 50 ⁇ m after the addition of the reactants and after an initial hold time of 30 minutes.
  • the slurry is controlled to a d50 psd of at least 60 ⁇ m after the addition of the reactants and after an initial hoid time of 30 minutes More preferably, the slurry is controlled to a d50 psd of at least 70 ⁇ m after the addition of the reactants and after an initial hold time of 30 minutes
  • the hold time of slurry before isolation is less than 16 hours, preferably less than 12 hours. Preferably, the hold time is more than 30 minutes. In one preferred aspect, the hold time of slurry before isolation, such as before step (c), from 30 minutes to 16 hours. In one preferred aspect, the hold time of slurry before isolation, such as before step (c), from 30 minutes to 12 hours. If hold time increases to more than 16 hours the crystallite size may increase and/or particle size change,
  • step (c) of the present method the mixed metal compound is separated from the slurry, to obtain a crude product having a dry solid content of at least 10 wt%.
  • the mixed metal compound is separated from the slurry, to obtain a crude product having a dry solid content of at least 15 wt% More preferably the mixed metal compound is separated from the slurry, to obtain a crude product having a dry solid content of at ieast 20 wt% in step (d) of the present method the crude product is dried either by
  • heating the crude product to a temperature of no greater than X 0 C refers to the heating the product such that the bulk temperature of the product is no greater than X 0 C
  • the temperature to which the product is exposed for example a drum temperature in the case of drum drying, or the temperature of the shell of the product may be greater than X 0 C when the bulk temperature of the product is X 0 C
  • step d(i) is followed, that is in step (d) the crude product is dried by heating the crude product to a temperature of no greater than 150 0 C and sufficient to provide a water evaporation rate of 0 05 to 1 5 kg water per hour per kg of dry product
  • step d(ii) is followed, that is in step (d) the crude product is dried by exposing the crude product to flash drying or spray drying at a water evaporation rate of 500 to 50000 kg water per hour per kg of dry product
  • the crude product is dried by heating the crude product to a temperature of no greater than 15O 0 C and sufficient to provide a water evaporation rate of 0 05 to 1 kg water per hour per kg of dry product, more preferably a water evaporation rate of 0 05 to 0 5 kg water per hour per kg of dry product, even more preferably a water evaporation rate of 0 09 to 0 5 kg water per hour per kg of dry product, most preferred a water evaporation rate of 0 09 to 0 38 kg water per hour per kg of dry product
  • the crude product is dried by heating the crude product to a temperature of no greater than 150 0 C, such as no greater than
  • the crude product is dried by exposing the crude product to a temperature of no greater than 150 0 C, preferably exposing the crude product to a temperature of no greater than 140 0 C, preferably exposing the crude product to a temperature of no greater than 130 0 C, preferably exposing the crude product to a temperature of no greater than 120 0 C 1 preferably exposing the crude product to a temperature of no greater than 110 0 C, preferably exposing the crude product to a temperature of no greater than 100 0 C, preferably exposing the crude product to a temperature of no greater than 90 0 C, preferably exposing the crude product to a temperature of from 60 to 150 0 C, preferably exposing the crude product to a temperature of from 70 to 150 0 C, preferably exposing the crude product to a temperature of from 60 to 140 0 C, preferably exposing the crude product to a temperature of from 70 to 140 0 C 5 preferably exposing the crude product to a temperature of from 60 to 130 0
  • step d(i) the crude product is dried to between 5-10 wt% moisture by exposing the crude product to a temperature from 35-90 0 C and sufficient to provide a water evaporation rate of 0 05 to 0 5 kg water per hour per kg of dry product
  • step d(ii) the crude product is dried by exposing the crude product to flash drying or spray drying at a water evaporation rate of 900 to 40000 kg water per hour per kg of dry product
  • step d(ii) the crude product is dried by exposing the crude product to flash drying at a water evaporation rate from 1500 to 50000 or exposing the product to spray drying at a water evaporation rate from 500 to 1500 kg water per hour per kg of dry product. More preferably either from 20000 to 50000 by flash drying or from 900 to 1 100 by spray drying
  • step d(ii) the crude product is dried by exposing the crude product to flash drying or spray drying at a water evaporation rate of 500 to 50000 kg water per hour per kg of dry product, a delta T from 0 30 to 0 80 and residence time of product in dryer of less than 5 minutes
  • step (d) of the present method between any one of steps (a), (b), (c) and (d) of the present method, one or more additional steps may be provided.
  • additional steps are encompassed by the present method
  • the crude product is washed prior to step (d)
  • An additional process step according to one aspect of the present invention comprises performing ion exchange on the mixed metal compound This may be performed at any time during the process, such as when present in the slurry, as a crude product or a dried product.
  • a preferred ion exchange is in respect of sulphate present in the mixed metal compound.
  • Ion exchange performed in respect of sulphate present in the mixed metal compound is preferably performed by exchanging sulphate with carbonate, for example by contacting the mixed metal compound with a carbonate containing solution.
  • the separation of the product may be performed by any suitable method
  • the mixed metal compound may be separated from the slurry by centrifugation
  • Different filtration methods may be utilized but a preferred aspect is obtained by a filtration method using centrifugation which combines filtration followed by washing and de-watering in one step
  • Another preferred aspect is obtained by a filtration method using a belt fitter which combines filtration followed by washing and de-watering in one step
  • the product may be further treated
  • the present invention encompasses products obtained by virtue of further treatment
  • the dried crude product is classified by sieving to a d50 average particle size of less than 300 ⁇ m, more preferably the dried crude product is milled to a d50 average particle size of less than 200 ⁇ m, more preferably the dried crude product is milled to a d5 ⁇ average particle size of less than
  • the dried crude product is milled to a d50 average particle size of 2 to 50 ⁇ m, more preferably the dried crude product is m ⁇ led to a d50 average particle size of 2 to 30 ⁇ m
  • less than 10% by weight of particles are greater than 106 ⁇ m in diameter, more preferably less than 5%. Most preferably, no particles are greater than 106 ⁇ m in diameter as measured by sieving
  • the product may be further treated.
  • the present invention encompasses products obtained by virtue of further treatment
  • the dried crude product is m ⁇ led More preferably the dried crude product is milled to a d50 average particle size of less than 10 ⁇ m, yet more preferably the dried crude product is milled to a d50 average particle size from 2-10 ⁇ m most preferred the dried crude product is milled to a d50 average particle size from 2-7 ⁇ m, yet most preferred the dried crude product is milled to a d50 average particle size of approximately 5 ⁇ m
  • the dried crude product is m ⁇ led to provide a surface area of 40-80 m a /g, more preferably to a surface area of 40-70 m 2 /g, even more preferably to a surface area of 45-65 m 2 /g, most preferred to a surface area of 50-60 rri 2 /g
  • the dried crude product is m ⁇ led to a d50 average particle size from 2-10 ⁇ m and a surface area of 40-80 m z /g compound
  • the dried product is not milled
  • the dried product has a d50 average particle size from 10-50 ⁇ m and a surface area of 80- 145 m 2 /g compound
  • the dried crude product has a water content of less than 15 wt%, preferabiy the dried crude product has a water content of less than 10 wt%, preferably the dried crude product has a water content from 1-15 wt%, preferably the dried crude product has a water content from 5-15 wt%, preferably the dried crude product has a water content from 5-10 wt%, preferably the dried crude product has a water content from 8-15 wt%, preferably the dried crude product has a water content from 8-11 wt%, based on the total weight of the dried crude product
  • the mixed metal compound has a dry solid content of at least 10 wt%
  • the mixed metal compound has a dry solid content of at least 15 wt%
  • More preferabiy the mixed metal compound has a dry solid content of at least 20 wt%
  • the mixed metal compound When dried, the mixed metal compound has a dry solid content of at least 80 wt% Preferably, the dried mixed metal compound has a dry solid content of more than 85 wt%. Preferably the dried mixed metal compound has a dry solid content of less than 99 wt%. More preferably the dried mixed metal compound has a dry solid content of less than 95 wt%.
  • the dried mixed metal compound has a dry solid content from 90 to 95 wt%
  • the compound has a average crystal size of less than 20nm (200A)
  • Preferabiy the compound has a average crystal size of from 100 to 200 A
  • the compound has a average crystal size of from 155 to 200 A
  • the compound has a average crystal size of from 1 10 to 195 A
  • the compound has a average crystal size of from 1 10 to 185 A
  • the compound has a average crystal size of from 1 15 to 165 A.
  • the compound has a average crystal size of from 120 to 185 A, Preferably the compound has a average crystal size of from 130 to 185 A Preferably the compound has a average crystal size of from 140 to 185 A Preferably the compound has a average crystal size of from 150 to 185 A Preferably the compound has a average crystal size of from 150 to 175 A More preferably the compound has a average crystal size of from 155 to 175 A. More preferably the compound has a average crystal size of from 155 to 165 A
  • the present invention provides a mixed rneta! comprising at least Mg 2+ and at least Fe 3+ wherein the molar ratio of Mg 2+ to Fe 3+ is 2.1 "!
  • the compound prepared by the present method may be any mixed metal compound comprising Mg 2+ and at least Fe 3+
  • the compound is a compound having a hydrotalcite structure
  • the compound is of the formula
  • M l! is one or more bivalent metals and is at least Mg 2* ;
  • M !!l is one or more trivalent metals and is at least Fe 3+ ;
  • a ⁇ " is one or more n-va!ent anions and is at least CO 3 2" ;
  • x / ⁇ yn 1
  • 0.1 ⁇ x such as O 2 ⁇ x, O 3 ⁇ x, 0.4 ⁇ x, or 0.5 ⁇ x.
  • 0 ⁇ y ⁇ 1 Preferably 0 ⁇ y ⁇ 0 B
  • 0 ⁇ y ⁇ 0 6 Preferably 0 ⁇ y ⁇ 0 4
  • 0 05 ⁇ y ⁇ 0 3 Preferably 0.05 ⁇ y ⁇ 0 2.
  • 0.1 ⁇ y ⁇ 0 2 Preferably 0,15 ⁇ y ⁇ 0 2
  • 0 ⁇ m ⁇ 10 Preferably 0 ⁇ m ⁇ 8.
  • 0 ⁇ m ⁇ 6 Preferably 0 ⁇ m ⁇ 4
  • 0 ⁇ m ⁇ 2 Preferably 0 ⁇ m ⁇ 1.
  • 0 ⁇ m ⁇ 0 7 Preferably 0 ⁇ m ⁇ 0.6
  • 0 1 ⁇ m ⁇ 0 6 Preferably 0 ⁇ m ⁇ 0 5
  • the number of water molecules m can include the amount of water that may be absorbed on the surface of the crystallites as well as interlayer water
  • the compound has an aluminium content of less than 5000 ppm, more preferably less than 1000 ppm, most preferred 100 ppm, most preferably 30 ppm
  • the total sulphate content of the compound is from 1 .8 to 5 wt%
  • total sulphate content it is meant content of sulphate that is present in the compound, This may be determined by well known methods and in particular determined in accordance with Test Method 1 .
  • the total sulphate is from 2 to 5 wt% preferably from 2 to 3,7 wt%, preferably from 2 to 5 wt%, preferably from 2 to less than 5 wt%, preferably from 2.1 to 5 wt% preferably from 2,1 to less than 5 wt%, preferably from 2 2 to 5 wt%, preferably from 2 2 to less than 5 wt%, preferably from 2 3-5 wt%, preferably from 2 3 to less than 5 wt%
  • the total sulphate content of the compound is from 1 8 to 4 2 wt%
  • total sulphate content it is meant content of sulphate that is present in the compound This may be determined by well known methods and in particular determined in accordance with Test Method 1
  • the total sulphate is from 2 to 4 2 wt% preferably from 2 to 3 7 wt%, preferably from 2 to 3 2 wt%, preferably from 2 to less than
  • 3 2 wt% preferably from 2 1 to 3 2 wt% preferably from 2 1 to less than 3 2 wt%, preferably from 2 2 to 3 2 wt%, preferably from 2 2 to less than 3 2 wt%, preferably from
  • the interlayer sulphate content of the compound is from 1 8 to 5 wt%, preferably from 1 8 to 3 2 wt%, preferably from 2 to 5 wt%, preferably from 2 to less than 5 wt%, preferably from 2 to 3 2 wt%, preferably from 2 to 3 1 wt%, preferably from 2 to 3 0 wt%
  • the interlayer sulphate content of the compound is from 2 1 to 5 wt%, preferably from 2 1 to 3 2 wt%, preferably from 2 1 to less than 3 2 wt% More preferably the interlayer sulphate content of the compound is from 2 2 to 5 wt%, preferably from
  • the molar ratio of Mg 2+ to Fe 3+ is 2 5.1 to 1 5-1 ,
  • the mixed metal compound has an aluminium content of less than 10000 ppm, the average crystal size of the mixed metal compound is from 10 to 20nm (100 to 200A), and the d50 average particle size of the mixed metal compound is less than 300 ⁇ m Preferably the d50 average particle size of the mixed metal compound is less than 200 ⁇ m
  • the present invention provides a mixed metal compound comprising at least Mg 2+ and at least Fe 3+ ,
  • the moiar ratio of Ug 2* to Fe 3+ is 2 5.1 to 1 ,5.1 ,
  • the mixed meta! compound has an aluminium content of less than 10000 ppm, the average crystal size of the mixed metal compound is from 10 to 20nm (100 to 200A), and the water pore volume of the mixed metal compound is from 0,25 to 0 7 cm 3 /g of mixed meta! compound
  • the water pore volume of the mixed metal compound is from 0 3 to 0 65 cm 3 /g of mixed metal compound
  • the water pore volume of the mixed metal compound is from 0 35 to 0 65 cm 3 /g of mixed metal compound
  • the nitrogen pore volume of the mixed metai compound is from 0 28 to 0.56 cm 3 /g
  • the term 'nitrogen pore volume' refers to the pore volume as determined in accordance with Test Method 14
  • the nitrogen pore volume of the mixed metal compound is from 0 28 to 0 56 cm 3 /g it has been found that the close correlation to the water pore volume is such that the water pore volume need not be determined
  • the present invention provides a mixed metal compound comprising at least Mg 2+ and at least Fe 3+ , wherein
  • the molar ratio of Mg 2+ to Fe 3+ is 2 5:1 to 1 5:1 ,
  • the mixed metal compound has an aluminium content of less than 10000 ppm, the average crystal size of the mixed metal compound is from 10 to 20nm (100 to 200A), and the nitrogen pore volume of the mixed metal compound is from 0 28 to 0 56 cm 3 /g.
  • the present invention provides a mixed metal compound comprising at least Mg 2+ and at least Fe 3+ ,
  • the mixed metal compound has an aluminium content of less than 10000 ppm, the average crystal size of the mixed metal compound is from 10 to 20nm (100 to 200A) 1 and the inieriayer sulphate content of the compound is from 1 8 to 5 wt% (such as from 1 8 to 3 2 wt%) Preferably the average crystal size of the mixed metal compound is from 12 to 20nm (120 to 200A) As discussed herein, the present invention provides a mixed metai compound comprising at least Mg 2+ and at least Fe 3+ ,
  • the mixed metai compound has an aluminium content of less than 10000 ppm, the average crystal size of the mixed metal compound is less than 20nm (200A), and the interlayer sulphate content of the compound is from 2 1 to 5 wt% (such as from 1.8 to 3 2 wt%) Preferably the average crystal size of the mixed metal compound is from 10 to 20nm (100 to 200A)
  • the present invention provides a mixed metal compound comprising at least Mg 2+ and at least Fe 3+ ,
  • the molar ratio Of Mg 2+ to Fe 3+ is 2 5:1 to 1.5:1 ,
  • the mixed metal compound has an aluminium content of less than 10000 ppm, the average crystal size of the mixed metal compound is less than 20nm (200A) 1 and the surface area is from 80 to 145m 2 per gram of compound
  • the compound has a d50 average particle size of from 10 to 350 ⁇ m (and preferably wherein the compound has not been subject to milling)
  • the compound has a d50 average particle size of from 10 to 300 ⁇ m
  • the compound has a d50 average particle size of from 10 to 210 ⁇ m
  • the compound has a d50 average particle size of from 10 to 100 ⁇ m.
  • the compound has a d50 average particle size of from 10 to 50 ⁇ m
  • the compound has a d50 average particle size of from 10 to 35 ⁇ m
  • the compound releases magnesium in an amount is less than 0 15 mmol magnesiurn/g compound The magnesium release is determined in accordance with Test Method 3
  • the present invention provides a mixed metal compound comprising at least Mg 2+ and at least Fe 3+ ,
  • the molar ratio of Mg 2+ to Fe 3+ is 2.5: 1 to 1 5: 1 ,
  • the mixed metal compound has an aluminium content of less than 10000 ppm, the average crystal size of the mixed metal compound is from 10 to 20nm (100 to 200A), the surface area is from 40 to 80 m 2 per gram of compound
  • the d50 average particle size of the mixed metal compound is less than 100 ⁇ m
  • the d50 average particle size of the mixed metal compound is less than 50 ⁇ m
  • the d50 average particle size of the mixed metal compound is less than 20 ⁇ m
  • the d50 average particle size of the mixed metal compound is less than 10 ⁇ m.
  • the d50 average particle size of the mixed metal compound is approximately 5 ⁇ m.
  • the water pore volume of the mixed metal compound is from 0.25 to 0.7 crrvVg of mixed metal compound, preferably the water pore volume is from 0.3 to 0,65 cm 3 /g of mixed metal compound, preferably the water pore volume is from 0.3 to 0 6 cm 3 /g of mixed metal compound
  • the nitrogen pore volume of the mixed metal compound is from 0 28 to 0 56 cm 3 /g of mixed metal compound
  • the interlayer sulphate content of the compound is from 2.2 to 5 wt% (such as from 1.8 to 3.2 wt%), and/or
  • M" is one or more bivalent metals and is at least Mg 2+ ;
  • M 111 is one or more trivative metals and is at least Fe 3+ ,
  • a n" is one or more n-valent anions and is at least CO 3 2" ,
  • x/ ⁇ yn is from 1 to 1.2 (preferably x/ ⁇ yn is from 1 05 to 1 15, preferably x/ ⁇ yn is 1)
  • the compound has an aluminium content of less than 100 ppm, preferably an aluminium content of less than 30 ppm
  • the interlayer sulphate content of the compound is from 1 8 to 5 wt% (such as from 1.8 to 3.2 wt%), and/or
  • the compound has a d50 average particle size of less than 100 ⁇ m. preferably the compound has a d50 average particle size of 5 to 50 ⁇ m, preferably the compound has a d50 average particle size of approximately 5 ⁇ m and/or
  • the water pore volume of the mixed metal compound is from 0.3 to 0.65 cm 3 /g of mixed metal compound and/or
  • the compound has a dry solid content of at least 20 wt%
  • the compound may have any degree of porosity, subject to any range specified herein
  • the water pore voiume of the mixed metal compound is from ⁇ 25 to ⁇ 7 cm 3 /g of mixed metal compound
  • the water pore volume of the mixed metal compound is from 0 3 to 0 65 cm 3 /g of mixed metal compound
  • the mixed metal compound comprises at least some material which is a Layered Double Hydroxide (LDH) More preferably, the mixed metal compound of formula (I) is a layered double hydroxide
  • LDH Layered Double Hydroxide
  • the term "Layered Double Hydroxide” is used to designate synthetic or natural lamellar hydroxides with two different kinds of metallic cations in the main layers and interiayer domains containing anionic species This wide family of compounds is sometimes also referred to as anionic clays, by comparison with the more usual cationic clays whose interlameliar domains contain cationic species LDHs have also been reported as hydrotalcite-like compounds by reference to one of the polytypes of the corresponding [Mg-AIj based mineral
  • a particularly preferred mixed metal compound contains at least one of carbonate tons, and hydroxyl ions
  • a particularly preferred compound contains as M" and M ⁇ s ⁇ , magnesium and iron (III) respectively
  • the mixed metal compound or compounds may be suitably made by co-precipitation from a solution, followed by centrifugation or filtration, then drying, milling and/or sieving The mixed metal compound may then be rewetted as part of the wet-granulation process and the resulting granules dried in a fluid-bed dryer The degree of drying in the fluid-bed is used to establish the desired water content of the final tablet
  • Two methods of coprecipitation may be used, namely one at low supersaturation whereby the pH of the reaction solution is maintained constant by controlling the addition of a second solution of an alkali, or alternatively precipitation at high supersaturation whereby the pH of the reaction solution is continuously changed by addition of the mixed metal solution to an alkali solution already present in the reactor vessel
  • the precipitation method whereby the pH is kept constant is preferred as this avoids the formation of single metal compounds such as M(OH) 2 and/or M(OH) 3 phases instead of mixed meta! compound
  • precipitation methods of the mixed metal compound may also be possible if the crystallite size is controlled to less than 200 A.
  • a precipitation method involving separate nucleation and aging steps an urea hydrolysis method, an induced hydrolysis method, a sait-oxide method, a sol-gel method, an electrosynthesis method, an in situ oxidation of the divalent meta! ion to a trivalent metal ion, a so-called "Chimie
  • the mixed metal compound may be formed by heating an intimate mixture of finely divided single metal saits at a temperature whereby solid-soiid reaction can occur, leading to a mixed metal compound formation.
  • Post synthesis methods that tend to promote ageing are less preferred but may be used if crystallite size is controlled to less than 200 A
  • Examples of possible post synthesis heat-treatment steps include hydrothermal, microwave and ultrasound.
  • a variety of methods can be used to separate the mixed metal compound from the reaction slurry. Different washing, drying and milling methods are also possible where crystallite size is less than 200 A
  • the substances of the invention prepared by treatment of a suitable starting material as hereinbefore described may be prepared by providing a first solution of a water soluble compound of metal M" and a water soluble compound of metal M 1 ", the anions being chosen so as not to result in precipitation from the first solution (A).
  • a second solution (B) is also provided, of a water soluble hydroxide (e g NaOH) and a water soluble salt of anion A ⁇ " (the cation being chosen so as not to precipitate with the hydroxide or the anion with the metal from the hydroxide)
  • the two solutions are then combined and the mixed metal compound starting material is formed by co-precipitation.
  • Solution A is made up by dissolving magnesium sulphate and ferric sulphate in purified water
  • Solution B is made up by dissolving sodium carbonate and sodium hydroxide in purified water
  • a heel of purified water is added to a reactor, the solutions A and B are fed in a ratio controlled manner. After the product forms in the reactor it may comprise solid crystalline material, usually also with the presence of some solid amorphous material.
  • the material so formed is of a layered double hydroxide and/or of a hydrotalcite structure, usually also with some amorphous and/or poorly crystalline material, preferably after co-precipitation, the material is then filtered or centrifuged, washed then dried by heating
  • the drying is carried out either by (i) exposing the crude product to a temperature of no greater than 15O 0 C and sufficient to provide a water evaporation rate of 0 05 to 1 5 kg water per hour per kg of dry product, or (ii) exposing the crude product to flash drying or spray drying at a water evaporation rate of 500 to 50000 kg water per hour per kg of dry product, for example by oven drying, spray drying or fluid bed drying
  • the dry material may be first classified, to remove oversize particles by milling and/or sieving and/or any other suitable technique, for example to restrict the material to be treated to particles which are substantially no greater than 300 ⁇ m in diameter
  • reaction equipment type may be controlled in order to carry out the reaction in the manner desired
  • reactant stream composition may be controlled in order to carry out the reaction in the manner desired
  • temperature and pH may all be specified in order to produce a desired reaction
  • mode of reactant addition may all be specified in order to produce a desired reaction
  • agitation system may all be specified in order to produce a desired reaction
  • hold time may all be specified in order to produce a desired reaction
  • reactor types are common in the pharmaceutical industry, these include Batch and Continuous reactors
  • the materia! structure and crystallite size can be significantly determined at the reaction stage by close control of the reactant solution concentration, the reaction temperature, the time that the reaction mass is held following precipitation and the mode of reactant addition Furthermore, in order to achieve the preferred material structure with small crystallite size, a high solution concentration (at end of reaction period of 4 8 - 5.4 wt%), low reaction temperature (15 - 25°C) and short hold time (typically ⁇ 12 hours) are preferred
  • the preferred M 2+ : M 3+ molar ratio between 1 5.1 to 2 5:1 of the mixed metal compound can be achieved by maintaining the reactant streams in solution even at relatively low temperatures, thereby limiting the reaction temperature
  • the reaction temperature can be important in determining the extent of crystallite growth and hence the phosphate binding activity
  • the preferred method allows good filtration rates to be achieved, this again can be important in limiting the reaction mass storage time which in term is known to help determine the extent of crystallite growth, and hence the phosphate binding activity
  • the mode of reactant stream addition can be important in defining the reaction product quality Different combinations of addition mode are possible and may include the addition of one reactant stream into an excess of the other reactant (either reactant could be selected as the added stream)
  • the reaction is carried out by simultaneous addition (co-precipitation) of a reactant stream containing carbonate and hydroxide ions, and a reactant stream containing metal and sulphate ions
  • the product can be removed on a continuous basis as the reactant streams are added, or at the end of a defined period
  • Good filtration characteristics are achieved by targeting a reiativeiy large particle size such as of at least 40 ⁇ m by controlling the power per unit voiume from 0 03 to 1 6 kW/m 3
  • power per unit volume of 0 05 to 0 5 kW/m 3 using impeller(s) configured for axial flow agitation helps to produce a slurry with further improved filtration characteristics (such as lower filtration and washing time, and high final solids content in cake)
  • agitation is used to subject the slurry to mixing under conditions providing a power per unit volume of 0 03 to 1 6 kW/m 3 provided by static mixers, impeller agitators, pump, jet mixer or dynamic in line mixer Therefore, in a further preferred embodiment, axial flow agitation is used to subject the slurry to mixing under conditions providing a power per unit volume of 0 03 to 1.6 kW/m 3 provided by an impeller agitator More preferably a power per unit volume of 0.05 to 0.5 kW/m 3 delivered by impeller agitation This provides reaction slurry with the preferred filtration characteristics,
  • the reaction is agitated using means other than a conventional impeller agitator
  • An optimum hold time has been identified as from 30 minutes to 12 hours
  • a wide number of options are available for carrying out the product isolation and washing steps, however the filtration equipment type and operating process parameters should be carefully defined and controlled For example, in order to limit the overall reaction slurry hold time (and hence crystallite growth), it is beneficial to minimise the time for cake isolation and wash time A high cake solids content is also preferable as this reduces the drying time and hence the propensity for crystallite growth during the drying step
  • Various filter types are used in the pharmaceutical industry, these include: Neutsche filters, Filter dryers, Filtering centrifuges, Belt filters, Plate and frame filters. When isolating the unaged mixed metal compound, the overall filtration rate can be extremely low due to the relative difficulty of isolating and washing these unaged clay- type mixed meta!
  • the unaged material of crystallite size of less than 200 A has the tendency to result in 'blinding' of the filtration media and/or the clay-type properties have a tendency to form a more impermeable cake.
  • the dryer type, mode of drying, and rate of drying should be specified and controlled such that the crude product is dried either by (i) exposing the crude product to a temperature of no greater than 150 0 C and sufficient to provide a water evaporation rate of 0 05 to 1 ,5 kg water per hour per kg of dry product, or (ii) exposing the crude product to flash drying or spray drying at a water evaporation rate of 500 to 50000 kg water per hour per kg of dry product.
  • the rate of drying is affected by factors including the mode of drying, heated surface/ heating medium temperature, degree of agitation, vacuum level (if any) etc
  • the product temperature must be limited to no greater than 150 0 C to prevent damage to the drug substance.
  • dryer types are common in the pharmaceutical industry, these include long residence time dryers (characterised as typically up to 20 h residence time) such as Spherical, Conical, Double cone, Tray dryer (vacuum, ambient pressure), and short residence time dryers (characterised as typically up to several minutes residence time) include; Spray, Spin flash, Etc.
  • the drying surface temperature is typically limited to 15O 0 C for batch drying and preferably 90 0 C or less to avoid average crystal size growth to above 200 A Partial evacuation of the dryer depresses the boiling point of water in the drying mass, thereby limiting crystal growth, this depression also serves to maximise the drying rate
  • the drying rate is manipulated by maximising the dryer vacuum and /or increasing the shell temperature up to 120 0 C during an initial drying phase, to remove water at the highest possible rate, and then reducing the rate by reducing the shell temperature to less than 90 0 C, in order to accurately target a defined moisture end point whilst maintaining a crystallite size less than 200 A
  • the moisture end point can be inferred by monitoring the evaporation mass, or measured directly, by analysis of the dried contents, or other suitabie methods
  • Conical dryers e g Nautamixer type
  • Vacuum tray dryers were found to produce an acceptable product quality, however this type of dryer can require manual intervention (e g redistribution of so ⁇ ds) for uniform drying, and has limited throughput.
  • the long residence time batch dryers described all have relatively low drying rates (expressed in normalised terms as kg evaporation per kg product per hour) when compared to the short residence time drying methods
  • long residence time batch drying tends to produce a relatively large average crystal size and relatively low pore volume and surface area
  • short residence methods such as spray drying and spin flash drying have been found to produce relatively smailer crystals with relatively large pore voiume and surface area
  • Spray dried material has the additional advantage of granulation for just dry blending (e g.
  • Long residence drying time methods are typically defined as having a residence time equal to or greater than 3 hours Examples of these include: tray drying, kettle drying, pan drying, rotary (shell) drying, rotary (internal) drying, double cone drying
  • evaporation rates of between 9 and 29 kg water/(h m 2 ) are achievable using an agitated vacuum spherical dryer Stated on an alternative basis this is equivalent to an evaporation rate of approximately 0 05 to 0 5 kg water per hour per kg of dry product
  • the product crystallite size produced at this range of evaporation rates is typically between 100 - 200 Angstroms
  • the dryer must be fed with a wet cake (typically > 20 wt% solids)
  • Short residence drying time method examples typically have much lower residence times These differ depending upon technology types and are defined as: spin flash drying, typical residence time of 5 to 500 seconds / spray drying, typical residence time up to 60 seconds
  • Typical evaporation rates are defined as. spin flash 70 - 300 kg water/(h m 3 ) vessel volume, spray 5 - 25 kg water/(h m 3 ) vessel volume Evaporation rates for spin flash and spray dryers are also calculated as 500 to 50000 kg water/(h kg drug) The product crystallite size produced at this range of evaporation rates is typically less than 140
  • the spin flash dryer may be fed with wet cake (typically > 20 wt% solids), whereas the spray dryer must be fed with a free flowing slurry at a Sower concentration (typically to 10 wt% solids)
  • the above short residence time dryers may all be operated on a continuous basis
  • the compound is used in the manufacture of a medicament for the prophylaxis or treatment of hyperphosphataemia
  • the present invention provides use of a compound of the present invention or obtained/obtainable in accordance with the present invention in the manufacture of a medicament for the prophylaxis or treatment of any one of hyperphosphataemia, renal insufficiency, hypoparathyroidism, pseudohypoparathyroidism, acute untreated acromegaly, chronic kidney disease and over medication of phosphate salts
  • Examples of one or more of the symptoms which may indicate risk for the presence of CKD' a creatine concentration of above 1 6 mg/dL, a blood phosphate level of above 4 5 mg/dL ( any detectable blood in urine, urine protein concentration above 100 mg/dL, a urine aibumin concentration above about 100 mg/dL, a glomerular filtration rate (GFR) of below 90 mL/min/1 73 m 2 or a parathyroid hormone concentration in the blood above 150 pg/mL
  • the symptoms are also defined by the National Kidney Foundation-Fidney Disease Outcomes Quality Initiative "NKF-K/DOQi" or "K/DOQI/ in one preferred aspect the chronic kidney disease (CKD) treated in accordance with the presence invention is CKD having stage one to five
  • the medicament may be used on animals, preferably humans
  • a pharmaceutically acceptable carrier may be any material with which the substance of the invention is formulated to facilitate its administration.
  • a carrier may be a solid or a liquid, including a material which is normally gaseous but which has been compressed to form a liquid, and any of the carriers normally used in formulating pharmaceutical compositions may be used
  • compositions according to the invention contain 0.5% to 95% by weight of active ingredient.
  • pharmaceutically acceptable carrier encompasses diluents, excipients or adjuvants.
  • Suitable formulations can be produced by known methods using conventional solid carriers such as, for example, lactose, starch or talcum or liquid carriers such as, for example, water, fatty oils or liquid paraffins
  • solid carriers such as, for example, lactose, starch or talcum
  • liquid carriers such as, for example, water, fatty oils or liquid paraffins
  • Other carriers which may be used include materials derived from animal or vegetable proteins, such as the gelatins, dextrins and soy, wheat and psyllium seed proteins; gums such as acacia, guar, agar, and xanthan, polysaccharides, alginates, carboxymethylcelluloses, carrageenans; dextrans; pectins; synthetic polymers such as polyvinylpyrrolidone, polypeptide/protein or polysaccharide complexes such as gelatin-acacia complexes, sugars such as mannitol, dextrose, galactose and trehalose
  • Suitable colouring agents include red, black and yellow iron oxides and FD & C dyes such as FD & C blue No. 2 and FD & C red No 40 available from Ellis & Everard Suitable flavouring agents include mint, raspberry, liquorice, orange, lemon, grapefruit, caramel, vanilla, cherry and grape flavours and combinations of these.
  • Suitable pH modifiers include sodium hydrogencarbonate, citric acid, tartaric acid, hydrochloric acid and maleic acid.
  • Suitable sweeteners include aspartame, acesulfame K and thaumatin.
  • Suitable taste-masking agents include sodium hydrogencarbonate, ion- exchange resins, cyclodextrin inclusion compounds, adsorbates or microencapsulated actives,
  • amounts of from 0 1 to 500, more preferably from 1 to 200, mg/kg body weight of substance of the invention as active compound are administered daily to obtain the desired results Nevertheless, it may be necessary from time to time to depart from the amounts mentioned above, depending on the body weight of the patient, the method of application, the animal species of the patient and its individual reaction to the drug or the kind of formulation or the time or interval in which the drug is applied In special cases, it may be sufficient to use less than the minimum amount given above, whilst in other cases the maximum dose may have to be exceeded. For a larger dose, it may be advisable to divide the dose into several smaller single doses Ultimately, the dose will depend upon the discretion of the attendant physician
  • a typical single solid unit dose for human adult administration may comprise from 1mg to 1g, preferably from 10 mg to 800 mg of substance of the invention
  • a solid unit dose form may also comprise a release rate controlling additive
  • the substance of the invention may be held within a hydrophobic polymer matrix so that it is gradually leached out of the matrix upon contact with body fluids
  • the substance of the invention may be held within a hydrophilic matrix which gradually or rapidly dissolves in the presence of body fluid.
  • the tablet may comprise two or more layers having different release properties
  • the layers may be hydrophilic, hydrophobic or a mixture of hydrophilic and hydrophobic layers
  • Adjacent layers in a multilayer tablet may be separated by an insoluble barrier layer or hydrophilic separation layer
  • An insoluble barrier layer may be formed of materials used to form the insoluble casing
  • a hydrophilic separation layer may be formed from a material more soluble than the other layers of the tablet core so that as the separation layer dissolves the release layers of the tablet core are exposed.
  • Suitable release rate controlling polymers include polyrnethacrylates, ethylcellulose, hydroxypropylmethylcellulose, methylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, sodium carboxymethylcellulose, calcium carboxymethylcellulose, acrylic acid polymer, polyethylene glycol, polyethylene oxide, carrageenan, cellulose acetate, zein etc
  • Suitable materials which swell on contact with aqueous liquids include polymeric materials include from cross-linked sodium carboxymethylcellulose, cross-iinked hydroxypropylcellulose, high molecular weight hydroxypropylcelluiose, carboxymethylamide, potassium rnethacrylatedivinyibenzene copolymer, polymethylmethacrylate, cross-linked polyvinylpyrrolidone and high molecular weight polyvinylalcohols.
  • Solid unit dose forms comprising a substance of the invention may be packaged together in a container or presented in foil strips, blister packs or the like, e g marked with days of the week against respective doses, for patient guidance,
  • a formulation in powder dose form could be either diluted in water, reconstituted or dispersed.
  • the compound of the present invention may be used as the sole active ingredient or in combination with another phosphate binding agent It may also be used in combination with a calcimimetic such as cinacalet, vitamin D or calcitrio!.
  • the present invention provides use of a compound of the present invention or obtained/obtainable in accordance with the present invention in the manufacture of a medicament for the prophylaxis or treatment of hyperphosphataemia.
  • the mixed metal compound is formed by the reaction of an aqueous mixture of magnesium sulphate and ferric sulphate with an aqueous mixture of sodium hydroxide and sodium carbonate
  • the precipitation is carried out at a pH of around 9.8 and a reaction temperature starting at around 22 °C and rising to up to 30 °C upon addition of reactants.
  • the resulting precipitate is filtered, washed, dried and milled
  • the molecular formula of layered double hydroxides can be measured by different methods The actual method used to determine the molecular formula of the examples herein was determined from the analysis of M !l / M ll! ratio (Method 1), SO 4 analysis (Method 5), CO 3 analysis (Method 6) and H 2 O analysis (Method 12).
  • Interiayer anions are also defined as bound anions or anions that cannot be removed by washing with water.
  • ⁇ y - is the sum of moles interiayer anion corrected with the formula normalisation factor
  • wt% H 2 O LOD (loss on drying measured at 105 0 C)
  • the ratio x / ⁇ y ⁇ can be calculated from the values of x and the sum of interlayer anions ( ⁇ yn) the data for which is inserted below into molecular formula IMg 1- x Fe x (OH) 2 ][(CO 3 ) y1 (SO 4 ) y2 mH 2 O] [Na 2 SO 4 J 2
  • reaction mixture was mixed for another 30 minutes and then filtered using a buchner filtration set up
  • the product slurry was filtered using a vacuum pump and buchner funnel with a WhatmanTM hardened ashless filter paper (No 541) After filtering, the filter cake was washed with portions of AnalaRTM water. The filtered product was then washed with 220 cm 3 portions of cold AnalaRTM water After isolation the product was dried using a preheated oven.
  • washed product was transferred to a vessel and dried in a preheated oven at 120 0 C for three hours.
  • Product sample for analysis were ground using a bail mill (Retsch PM 100) The milling parameters were set depending on the properties of the product.
  • Product sample for analysis was milled through a stainless steel, 200mm diameter, 106 ⁇ m sieve, using a sieve shaker (Retsch AS-200) Oversize material was returned to the stock dried sample to be reground, until all materia! is ⁇ 106 ⁇ m
  • Example 2
  • the slurry is refluxed for 4 hours by using a hot plate and a Liebig condenser to reflux the sample in a sealed flask.
  • the sample was then immediately filtered using a Buchner funnel under vacuum
  • the aged compound was then isolated using the same method as described for Example 1
  • Precipitation pH 10 5; reaction temperature is 30 Celsius; 2 7 moles excess Na 2 CO 3 [Mg 065 Fe 0 34 (OH) 2 K(CO 3 )0 14 (SO 4 )O O 2 O 23H 2 O] [Na 2 S0 4 ] 0 oo
  • Precipitation pH 10 5; reaction temperature is 30 Celsius; 1 moles excess Na 2 CO 3 [Mg 0 6/Fe 0 33(OH) 2 ][(CO 3 ) 013 (SO 4 ) ⁇ 02 .0.38H 2 O] [Na 2 SO 4 J 0 oo
  • Precipitation pH 10.1 ; reaction temperature is 30 Celsius; 2 7 moies excess Na 2 COa [Mg 0 6S Fe 0 34 (OH) 2 ][(C0 3 )o i ⁇ (S0 4 )o 02 O 37H 2 O) [Na 2 SO 4 Jo oo
  • Precipitation pH 9 8; reaction temperature is 30 Celsius 2 7 moles excess Na 2 CO 3 [Mg 066 Fe 03 4(OH) 2 ][(CO 3 ) ⁇ i2 (S ⁇ 4)Q 03. 0.65H 2 O][Na 2 SO 4 ]O
  • Precipitation pH 9,8; reaction temperature is 30 Celsius; 4 moles excess Na 2 CO 3 [Mg 0 ⁇ rFe 033 (OH) 2 ][(CO 3 ) Q i 3 (S0 4 )o os-0 38H 2 O] [Na 2 SO 4 ]O oo
  • Precipitation pH 11; reaction temperature is 15°C; 1 moles excess Na 2 CO 3 [Mg 0 64Fe 036 (OH) 2 H(CO 3 )O 12 (SO 4 )O O 3 .ndH 2 O] [Na 2 SO 4 Jo oo
  • Precipitation pH 9.6; reaction temperature is 30 Celsius; 2 7 moles excess Na 2 CO 3 [Mg 0 B 4 Fe 0 36 (OH) 2 ][(C0 3 )o i_(SO 4 ) 0 O 4 -O 56H 2 O] [Na 2 SO 4 J 0 oo
  • Precipitation pH 9 5; reaction temperature is 30 Celsius; 2,7 moles excess Na 2 CO 3 [Mg 062 Fe 0 38 (OH) 2 ][(C0 3 ) 0 12 (S ⁇ 4)o 04 0.49H 2 OPa 2 SO 4 J 00 O
  • Precipitation pH 9.5; reaction temperature is 30 Celsius; 4 moles excess Na 2 CO 3 23 [Mg 0 64Fe 0 3B(OH) 2 ]KCO 3 )O 12 (SO 4 ),, 04 0 52H 2 O][Na 2 SO 4 J 0 oo Crystallite size: not determined (nd)
  • Example 28 To make 163 kg of the mixed metal compound (dry basis) two starting solutions were prepared designated solution A and solution B To prepare solution A, 138 kg (dry basis) iron sulphate of 40.4 to 42 9 wt% ferric sulphate of water industry standard suitable for human consumption conforms to BS EN 890:2004, 166 kg (dry basis) magnesium sulphate (added as the hepta-hydrate) were dissolved in a total of 1034 kg of water where this total water amount includes the water associated with the ferric sulphate solution. To prepare solution B, 173 kg sodium hydroxide and 129 kg sodium carbonate were dissolved in 948 kg of water to provide homogenous solutions.
  • the reaction vessel water heel was 840 kg The water supplied to the heel was 30% of the total water supplied
  • the reactant solution temperatures are adjusted to around 22°C prior to addition
  • the reactant streams (solutions A and B) are then simuitaneously fed to the reaction vessel at a rate such as to maintain a reaction pH of 9 8. Cooling of the vessel contents is applied such as to maintain a temperature of 20-25 0 C.
  • a heel of purified water is introduced prior to the introduction of the reactant streams in order to enable agitation of the vessel in the initial reaction phase and to give a final slurry concentration of around 5 1 wt% compound
  • the vessel is agitated using a high turnover, low shear axial flow agitator operating at a power per unit volume of 0,1 kW/rn 3 and where the reactant solutions are delivered to an area of high turnover
  • the reactor is baffled in order to promote good mixing
  • the precipitate slurry is held in the reaction vessel (also referred to as hold time) for up to 12 hours and is transferred in aliquots to a vertical filtering centrifuge for isolation and washing, using purified water so as to provide maximum product rate. Washing is terminated to achieve a residua! sodium content (expressed as Na 2 O in the dried product) of less than 0 40 wt%.
  • the wet cake is discharged from the centrifuge and is dried in a spherical, agitated vacuum drier Vacuum and shell temperature are adjusted to provide a product temperature in the dryer of approximately 72°C
  • the rate of drying was 0 26 kg water/(kg dried product hr) a residence time of 12 hours and a product rate per unit area of 4 6 kg product /(m 2 hr)
  • the dried product is first coarse milled using a de-lumptng mill to a particle size distribution (Test Method 24) of typically 200 micron (D50) followed by final micronisation to a particle size of typically 5 micron (D50).
  • the pattern of mixing is demonstrated via particle tracks from each of the two reactant stream inlets and shows that the streams remain effectively segregated from each other before the fluid has dispersed widely into the butk Contours of concentration were also generated and confirm that mixing into the bulk takes place very rapidly,
  • Kenics KM static mixer may be suitable to provide a volume in which the reaction can take place and suitable to deliver the necessary mixing regime
  • the Kenics KM static mixer using a notional feed zone volume of SxIO "4 m 3 , to provide a power to mass ratio (1 28 W/kg - equivalent to 154 kW/m 3 ) and residence time (1 25 sec)
  • the resulting diameter was 100 mm and the flowrate 280 litre/min.
  • the wet cake is discharged from the Neutsch filter and is dried in a vacuum tray oven where the oven wails are heated to 120 to 130 0 C and regular manual redistribution of the drying mass is carried out
  • the rate of drying was 0 38 kg water/ ⁇ kg dried product hr) with a total drying time of 12 to 16 hours and a product rate per heated dryer surface area of 0,2 kg product /(m 2 h)
  • the dried product is micronised using an impact mill to a particle size of typically 5 micron ⁇ D50, Test Method 24).
  • Example The actual molecular formula found by analysis was- 31 [Mg 0 66Fe 034 (OH) 2 K(CO 3 ) O i 2 (S0 4 )o 02 0 28H 2 O] [Na 2 SO 4 ]Q 0
  • a reaction slurry was prepared according to the method of example 2 but with a reaction pH of 9 6, a liquid ferric source (a solution 40.4 to 42,9 wt% ferric sulphate of water industry standard suitable for human consumption conforms to BS EN 890:2004) and a nominal 400 cm 3 batch size.
  • a reaction pH of 9 6 a liquid ferric source (a solution 40.4 to 42,9 wt% ferric sulphate of water industry standard suitable for human consumption conforms to BS EN 890:2004) and a nominal 400 cm 3 batch size.
  • reaction slurry was washed using Tangential Flow Filtration (Sartorius Slice 200 bench top system with 200 cm 2 filtration area, PESU 0 1 micron membrane) operated in constant rate mode
  • the system was flushed and filled with Dl water prior to filtration, the permeate rate was regulated to prevent filter blockage Filtration with wash water addition (diafiltration) was carried out to achieve a residual sodium content (expressed as Na 2 O in the dried product) of less than 0.40 wt%.
  • the washed slurry was then concentrated using conventional vacuum filtration and dried in a laboratory oven. Example The actual molecular formula found by analysis was.
  • Example 34 As for example 33 but with a reaction pH of 10 1
  • Example 35 As for example 33 but with a reaction pH of 10 1
  • Example 35
  • a reaction slurry was prepared for processing according to the method of Example 28, However, 620 kg of reaction slurry were subsequently processed using Tangential Flow Filtration instead of centrifugat ⁇ on A reaction pH of 9,8 was used. Prior to filtration, to reduce the risk of membrane blockage, the reaction slurry was circulated through a wet colloid mill in order to reduce the D50 particle size (Test Method 9) from 60 to 51 micron A Sartorius Sartoflow Beta filtration unit was used with eleven Sartocon Il membranes giving a total filtration area of 7 7 m2 The system was flushed and filled with Dl water prior to filtration, the permeate rate was regulated to prevent filter blockage A rotary lobe pump was used to circulate slurry through the system at an inlet pressure of between 2 and 3 5 bar and a typical retentate flow of 3400 l/h Filtration with wash water addition (diafiltration) was carried out until to achieve a residual sodium content (expressed as Na 2 O in the dried product) of less
  • the rate of drying was approximately 0 27 kg water/(kg dried product hr), a residence time of 13 hours, a product rate per unit area of 1 4 kg product /(m 2 hr), and the maximum dryer temperature achieved is approximately 85 0 C
  • the rate of drying was approximately 0 38 kg water/(kg dried product.hr), a residence time of 9 hours and a product rate per unit area of 1.2 kg product /(m 2 hr).
  • the rate of drying was approximately 0.21 kg water/(kg dried product.hr) a residence time of 18 hours and a product rate per unit area of 0 1 kg product / ⁇ m 2 ..hr)
  • the rate of drying was approximately 0,27 kg water/(kg dried product.hr) a residence time of 16 hours and a product rate per unit area of 0.2 kg product /(m 2 hr)
  • the rate of drying was approximately 0 33 kg water/(kg dried product hr), a residence time of 9 8 hours and a product rate per unit area of 1 6 kg product /(m 2 hr) and the maximum dryer temperature achieved is approximately 76 0 C
  • the rate of drying was approximately 0 28 kg water/(kg dried product hr), a residence time of 10 3 hours and a product rate per unit area of 1 5 kg product /(rn 2 hr) and the product temperature achieved is approximately 64 0 C
  • Example 2 As for Example 2 but the method was then varied in that they were conducted at different pH, different excess of Na 2 CO 3 and different ferric source in accordance with Table 12.
  • Example 62 was prepared with aluminium sulphate in place of iron sulphate
  • XRF analysts of the product was performed by using a Philips PW2400 Wavelength Dispersive XRF Spectrometer, The sample was fused with 50:50 lithium tetra/metaborate (high purity) and presented to the instrument as a glass bead All reagents used were analytical grade or equivalent unless specified.
  • a muffle furnace capable of 1025 0 C, extended tongs, hand tongs, Pt/5%Au casting tray and Pt/5%/Au dish were used.
  • the XRF method was used to determine the Al, Fe, Mg, Na and total sulphate content of the compound as well as the Mil to Mill ratio Test Method 2 X-Ray Diffraction (XRD) measurements
  • Powder X-ray diffraction (XRD) data were collected from 2-70 degrees 2theta on a Philips PW 1800 automatic powder X-ray diffractometer using copper K alpha radiation generated at 4OkV and 55mA, a 0 02 degree 2theta step size with a 4 second per step count time, An automatic divergence slit giving an irradiated sample area of 15 x 20mm was used, together with a 0 3mm receiving slit and a diffracted beam monochromator
  • the approximate volume average crystallite size can be determined from the width, at half peak height, of the powder X-ray diffraction peak at about 11.5 degrees 2 theta (the peak is typically in the range 8 to 15 degrees 2 theta for hydrotatcite type materials) using the relationship given in Table 1 which is derived using the Scherrer equation
  • the contribution to the peak width from instrument line broadening was 0 15 degrees, determined by measuring the width of the peak at approximately 21 4 degrees 2theta of a sample of LaB 5 (NIST SRM 660) under the same conditions Table 1 XRD Peak width conversion to crystallite size using the Scherrer equation
  • ⁇ wavelength of radiation used (in A)
  • ⁇ peak width measured as FWHM (full width at half maximum height) and corrected for instrument line broadening (expressed in radians)
  • the width of a peak is the sum of two sets of factors, instrumental and sample.
  • the instrumental factors are typically measured by measuring the peak width of a highly crystalline sample (very narrow peaks) Since a highly crystalline sample of the same material is not available, LaB 6 has been used For the current measurements an instrument value of 0 15 degrees has been used
  • the peak width due to instrumental factors should be subtracted from the measured peak width i e : p " ⁇ ⁇ (measured) ⁇ b(jnstrumental)
  • the peak width (as FWHM) has been measured by fitting of a parabola or another suitable method to the peak after subtraction of a suitable background Peak position
  • the phosphate binding capacity was determined by:
  • Phosphate binding (rnmo!/g) S P (mmol/l) - T P (rnmol/l) / W (g/l) where.
  • MCT peptide2+, food supplement (SHS International) was mixed to form a slurry of 20% (w/v) in 0 01 M HCi Separate aliquots of 0 05 g dry compound were mixed with 5 cm 3 of the food slurry and constantly agitated for 30 minutes at room temperature A 3 cm 3 aliquot was removed and centrifuged at 4000 rpm for 10 minutes, and the phosphate and magnesium in solution were measured.
  • interlayer SO4 (wt%) interlayer S04 (mole) x molecular weight S04
  • a sample of known mass is combusted at around 1350 °C in a furnace in a pure oxygen atmosphere Any carbon in the sample is converted to CO 2 which is passed through a moisture trap before being measured by an infra-red detector
  • the carbon content of the sample can be found
  • a Leco SC-144DR carbon and Sulphur Analyser, with oxygen supply, ceramic combustion boats, boat iance and tongs was used 0 2 g (+/-0.01 g) of sample was weighed into a combustion boat. The boat was then placed into the Leco furnace and the carbon content analysed The analysis was performed in duplicate
  • the % C was determined by
  • %C (sample) ( 0 ZoC 1 + %C 2 )/2
  • Wash time was measured in minutes rounded to the nearest minute, it was the time it took for one wash (i e one wash volume of water) to be drawn through the filter The wet cake was not allowed to dry or crack during this period The time was measured using a stop clock Test Method 8 Filtration Time (Lab scale)
  • Filtration time was measured in minutes rounded to the nearest minute, it was the time taken for the slurry to be drawn through the filter, but the resulting wet cake was not allowed to dry. The time was measured using a stop clock.
  • Test Method 11 F i itrati o n Rate, ⁇ kg, dry, ,p roducj/m ⁇ .h)
  • Filtration Rate ⁇ kg dry product/m 2 h is defined as the mass of wet cake, expressed as dried compound, isolated, washed, dewatered and discharged per hour, divided by the area of filter used.
  • the moisture content of mixed metal compound is determined from the loss of weight (LOD) foliowing drying at 105'C for four hours at ambient pressure in a laboratory oven
  • the water pore volume is calculated as follows. -
  • Test Method 16 Total water added/kg API - granulation point This is the amount of water added to a dry mixture of 80wt% mixed metal compound and 20wt% excipients in order to form granulates (i e until a granulation point is reached)
  • Test Method 17 Tablet Volume The tablet volume is calculated from the dimensions of the tablet using a computer design package (iHolland Ltd).
  • Test Method 18 Rate of drying For the calculation of rate of drying (kg water/(kg dried product.hr)) mass of water removed during drying per unit time was divided by the mass of dry product produced. The time used to calculate the rate of drying is the dryer residence time defined in Test Method 19. Test Method 19 Dryer Residence Time
  • the residence time is the time during which water is removed from the material being dried.
  • the residence time is calculated as follows
  • the internal volume of the dryer is first determined The residence time of the air or gas fed to the dryer is then calculated by dividing the interval volume by the air or gas flow rate It is assumed, since a significant build up of solids does not occur within the dryer, that the average particle residence time is approximately equal to the air or gas residence time
  • the Product rate per unit area kg product/(m 2 hr) can be calculated by dividing the mass of dry product produced per unit time with the surface area used for heating
  • Delta temperature is defined for short residence drying processes as (T, n - T out )/ Tm where
  • Tm inlet gas temperature
  • T 0Ut t the outlet gas temperature or product temperature, 0 C (assuming gas and product are at the same temperature)
  • Test Method 22 Tapped Bulk Density Tapped Bulk Density was determined using a Copley JV1000 Auto tapper The measurement was made by the addition of the product (50.Og, +/- 5 Og) into a clean measuring cylinder (dedicated for the apparatus) The exact weight was noted The initial volume was noted The cylinder was then placed on the auto tapper and the machine was set for 3750 taps by entering the number of taps required and then pressing start The volume of the cylinder was taken again when the total number of taps was completed (end volume) The tapped bulk density was calculated as follows,
  • the Carr index was calculated using the following formula and the data available from the Tapped Bulk Density test,
  • Carr Index (%) 100 * ((initial volume (ml) - end volume (ml)) / initial volume (ml))
  • the particle size was determined using a Mastersizer 'S' fitted with a 300Rf iens and a DIF 2012 dispersion unit
  • the data was interpreted and analysed using Malvern Mastersizer software.
  • the Malvern was connected to process water supply.
  • the following program parameters were used, 80% pump speed, 80% stirrer speed, 50% ultrasonic and 3 minute residence time
  • the background level was checked to be beiow 100 units
  • the analysis commenced automatically.
  • the residual was checked to be less than 1 %.
  • the metals were determined by acidifying the samples first followed by analysis using ICP-MS Total heavy metal content (ppm) was then calculated by summating the following metals; As (ppm) + Cd (ppm) + Pb (ppm) + Hg (ppm) + Sb (ppm) + Mo (ppm) + Cu (ppm)
  • Test Method 27 Power per Unit Volume Computational Fluid Dynamics (CFD) software application was used to simulate fluid flow within the reaction vessel to establish mixing requirements in mixing equipment.
  • CFD Fluid Dynamics
  • the presence of a second anion-type may be possible.
  • the presence of only one anion-type may be considered more desirable than a mixture of anions
  • interlayer sulphate needs to be reduced further to achieve an even higher purity (i e less than 1 0 wt% interlayer sulphate ) and initial isolation and washing rates are not to be reduced it may be possible to wash the filter cake again but this time with a solution of Na 2 CO 3 (preferably up to 1 M concentration) followed by washing with water.
  • This process may reduce or remove the remaining interlayer sulphate without necessarily reducing filtration rates or phosphate binding
  • the compound is first washed with water to remove soluble SO 4 and sodium, followed by a wash with a Na 2 CO 3 solution to remove the interlayer sulphate, followed by a final wash with water to remove any remaining soluble ions
  • the compound is slurried with some Na 2 CO 3 solution for up to 1 hour to enable exchange of the interlayer sulphate for the carbonate It is believed that washing with excess Na 2 CO 3 would encourage removal of any remaining sulphate from the interlayer region
  • an AI-free mixed metal compound with less than 1 wt% interlayer sulphate (preferably less than O 5 wt%) and less than O 5 wt% soluble sulphate.
  • Interlayer Sulphate A high filtration rate and a low wash time are advantageous when seeking to manufacture the MgFe mixed metal compounds on a commercial scale and to prevent crystallite growth
  • mixed metal compounds consisting of low interiayer sulphate levels (less than 1 8 wt%) are more difficult to filter and wash whereas if too high in sulphate (above 5 wt%) then washtime increases again (Table 3 and Figure 1)
  • interlayer sulphate levels can be maintained between 2-5 wt% by controlling the temperature of the reaction slurry, pH during the reaction and a Na 2 CO 3 (XS) excess range of either one of the following combinations shown below
  • a M 2+ :M 3* molar ratio of 2-1 and an assumed anion charge n 2 (i.e. as for CO 3 2" or SO 4 2" ) would result in a predicted value for (Ccaic) of 0, 17.
  • the experimental value for C exp can be determined from the sum of the amount (mole equivalent) of sulphate and carbonate anion
  • the ⁇ is defined as the difference between the C calculated and C experimental wherein a lower ⁇ value indicates a more pure hydrotalcite phase The smallest ⁇ value is observed when precipitating above pH 9.5.
  • the Na 2 CO 3 had to be of more than 2 mole excess
  • the precipitation pH has to be less than 10 and of 2.7 moles excess Na 2 CO 3 or less
  • Sodium carbonate not only provides the carbonate for the anion-exchange sites, but also acts as a pH buffer which assists pH control during precipitation.
  • the ability to maintain an accurate precipitation pH is considerably increased when NaaCO 3 is present and for that reason an excess of Na 2 CO 3 of more than 2 is preferred.
  • an excess Na 2 CO 3 of 4 or above is less preferred because this could result in an increased risk of incomplete dissolution of Na 2 CO 3 in the reacta ⁇ t solution at the preferred reaction temperatures (of less than 25 0 C) when preparing unaged mixed metal compounds.
  • the solution temperature may rise to 65 0 C and we found that an excess in Na 2 CO 3 of 4 or more does dissolve; however, cooling and/or pressurisation was required during dissolution to limit evaporation and to lower the temperature to the same value as that required for the reaction to prevent ageing
  • the Na 2 CO 3 solution (of more than 4 moSe excess) is cooled from 65 to 25 0 C partial precipitation of the Na 2 CO 3 occurs
  • PSD Particle Size Distribution
  • the slurry hold time is defined as the time period between when the addition of Solutions A and B ceases (reaction phase ends) and the last aliquot of slurry is added to the filtration equipment At pilot plant and large commercial scale where centrifuges are used, the slurry hold time is typically up to 12 hours since multiple aliquots of reaction mass are isolated, washed, dewatered and discharged as wet cake
  • the specific reaction agitation configuration to maintain low shear conditions whilst at the same time enabling sufficient mixing were also found to be useful in obtaining a preferred psd of more than 70 microns (when measured at the end of hold time).
  • the specific power input has to be controlled such as to avoid a rate which is too low but not at a rate which breaks the particles down into very fine particles of psd less than 70 microns
  • a filtration method is used to isolate the product from slurry form, wash to a predetermined impurity end point and de-water the cake in order to obtain a material of sufficiently high solids content to facilitate handling and for efficient drying.
  • de-watering is typically not carried out due to the limitations of the equipment used and due to small quantities handled Tangential Flow Filtration (TFF)
  • a method whereby filtration rate increases when psd is less than 70 microns is the Tangential Flow Filtration (diafiltration) method (Table 4 and 5); however, diafiltration in general has significantly lower filtration rates (at all psd ranges) and is only suitable for filtration of diluted slurries of more than 94 wt% moisture content Reaction slurry could be washed, but not concentrated, since moisture contents below approximately 94 wt%, would lead to blockage of the TFF The washed slurry would then require much greater energy input during drying Consequently, separation by diafiltration is less preferred Neutsche Filter
  • a belt filter is preferred as we found that these could be operated with a cake depth range of 15-25 mm at relatively high filtration rates This filtration method provides high filtration rates when psd is maintained above 70 microns
  • Table 6 shows how pore volume and surface area affects the control of phosphate binding capacity, storage stability, the granulation process and the production of tablets.
  • hydrotaicite type materials of a higher surface area may be expected to have a higher ion exchange capacity and thereby higher phosphate binding; this can be seen from Example 66 which has a high surface area of 1 19 m 2 /g and also a high phosphate binding value- However, the materia!
  • the material of crystallite size less 200 A binds greater than 80% of phosphate within 10 minutes (according to Test method 3 but measured at different time intervals) when maintained at a average particle size less than 100 ⁇ m, preferably less than 50 ⁇ m, most preferred less than 10 ⁇ m and a surface area more than 40 m 2 /g.
  • v ⁇ Manufacture of unaged, porous mixed metal compounds (drying)
  • the surface area of the drug substance is determined by a combination of rate of drying, residence time, product rate per unit area and delta T (Table 7).
  • the rate of drying is affected by both the mode of drying and other process parameters, such as the product temperature, heating surface/ gas temperature
  • a product of crystallite size between 90 and 200 A and a surface area (by N 2 ) of between 40-80 m 2 /g, and/or pore volume (by N 2 ) of between 0 10-0 28 cm 3 /g, and/or pore volume (by water) of between 0 3-0 6 cm 3 /g can be achieved by exposing the crude product to a product temperature of more than 80 but no greater than 15O 0 C and provide a rate of drying (water evaporation rate) of between 0 05 to 0.5 kg water per hour per kg of dry product and/or provide a dryer residence time of between 10 minutes to 30 hours and/or a product rate per unit area of between 0-7 kg product / (m 2 hr) typically achieved by use of a high residence time dryer under a vacuum of pressure of 400 mbar (absolute) or less.
  • a product of low pore volume (by water) range of 0 3-0 6 cm 3 /g can be obtained by a combination of the centrifuge and use of
  • a product of crystallite size less than 140 A and a surface area (by N 2 ) of between 80-150 m 2 /g, and/or pore volume (by N 2 ) of between 0 28-1 0 cm 3 /g, and/or pore volume (by water) of between 0 6-1 2 cm 3 /g can be achieved by exposing the crude product to a product temperature of more than 35 0 C but no greater than 15O 0 C and provide a rate of drying (water evaporation rate) of between 500 to 50000 kg water per hour per kg of dry product and/or provide a dryer residence time of less than 10 minutes and/or a delta T of between 0 2 to 1 0 typically achieved by use of a short residence time dryer
  • Table 8 shows that the drying must be sufficiently rapid so as minimise crystal growth, however bulk product temperatures exceeding 150°C must be avoided in order to prevent damage to the characteristic material structure.
  • Factors such as agitation during drying in long residence time dryers were also found to effect crystallite size. For example, dried samples (such as obtained by Neutsche / Tray Oven) whereby no continuous agitation is applied tend to show smaller crystallite size than those obtained by a spherical drier. Therefore an optimum drying regime exists
  • the surface area (by N 2 ) is between 40-80 m 2 /g
  • pore volume (by N 2 ) is between 0 10-0 28 crrvVg
  • the pore volume (water) is from 0 3-0 6 cm 3 /g
  • 100 to 200 A are preferably obtained by use of a long residence agitated drying process such as an agitated spherical dryer wherein the rate of drying is between 0,09 to 0 31 kg water/(kg dried product hr), more preferably a rate of drying between 0.24 to 0 31 kg water/(kg dried product hr) and/or a Product rate per unit area (kg product/m 2 hr) of between 1-10 more preferably between 2-7
  • a long residence agitated drying process such as an agitated spherical dryer wherein the rate of drying is between 0,09 to 0 31 kg water/(kg dried product hr), more preferably a rate of drying between 0.24 to 0 31 kg water/(kg dried product hr) and/or a Product rate per unit area (kg product/m 2 hr) of between 1-10 more preferably between 2-7
  • the advantages of the lower surface area product of crystallite size between 100 and 200 A and/or low surface area 40-80 m 2 /g and/or low pore volume (water) 0,3-0.6 crn 3 /g prepared by a long residence drying process are good phosphate binding, storage stability and a denser material that can be processed into a dosage form that is smaller thereby improving tablet pill burden
  • Average crystal size of less than 200 A has the advantage of good, controlled phosphate binding
  • a average crystal size of between 120-200 A is preferred if product is dried to a moisture content less than 15 wt% (preferably between 5-10 wt%) of a batch size of between 50 and 1000 kg when dried by a process of long residence drying with a agitated spherical dryer and when preparing materials of a low surface area of between 40 and 80 m 2 per gram and/or pore volume (water) of 0.3-0 6 cm 3 /g.
  • the low porosity product is preferably prepared from batch sizes between 50 and 1000 kg with a dryer residence
  • the dry material may be first classified to remove oversize particles by milling and/or sieving (ix) Effects of PSD on phosphate binding and magnesium release
  • Mg release remains constant whereas phosphate binding changes as a function of particle size (Table 9) This is a surprising result as a smaller particle size distribution could be expected to have a larger surface area and therefore more susceptible to Mg release
  • the magnesium release does not appear to be significantly affected by changes in surface area when maintained at less than 80 m 2 /g despite being milled to a particle size distribution (psd) with a (d50) of less than 60 micron when using this route.
  • the constant Mg release enables a wider selection of a preferred psd range to improve phosphate binding without compromising Mg release.
  • the data from Table 9 shows that a preferred particle size d50 is less than 177 micron, more preferably less than 114, most preferred less than 60 micron
  • Table 10 shows that if the crystallite size is too Sow (i e. of 120 A or less) the milling rate will be reduced by more than 50% when compared to that of crystallite size of 195 A which will present difficulties at scale when milling to a particle size distribution with a d50 of !ess than 1 14 micron
  • problems with occurrence of non-hydrotalcite phases such as MgO periciase, reduced milling rate or decomposition of the product because of over-heating of the product can occur
  • the crystallite size is less than 120 A it is preferred to use the short residence drying route which does not require milling Table 10 Effect of crystallite size on milling rate and phosphate binding
  • Control of material hardness is also important because this may also increase the potential for pickup of low levels of trace-metals from the milling equipment
  • the material is harder it also has to be milled harder which in turn can lead to higher temperatures being generated during milling which provide a milled material which can contain decomposition products or may be too dry (iess than 5 wt% moisture content as determined by LOD) which in turn can lead to problems with handling and the downstream processing (xi)
  • Methods of micronisation if the moisture content of the unmilled product is above 10 wt% then the product can become too sticky for milling whereas if less than 5 wt% the product after milling will be too dry and would then be less stable upon storage and/or provide problems in processing into tablet formulations.
  • the chemical (i.e. molar ratio of Mg. Fe of 2.1) and physical properties (i e surface area and particle size) of the mixed metal compounds composition favour equilibration to a 5- 8 wt% moisture content and as such may be less stable upon storage (i.e have a tendency to re-hydrate) if manufactured to a moisture content less than 5 wt%,
  • the present invention provides a mixed metal compound wherein the average crystal size of the mixed metal compound is less than 20nm (200A); in this aspect preferably the surface area is from 80 to 145 m 2 per gram.
  • the data from Table 1 1 shows that for a mixed metal compound with a surface area from 80 to 145 m 2 per gram the preferred particle size d50 is less than 343 micron, more preferably less than 296, even more preferably less than 203, most preferred less than 31 micron.
  • Table 11 shows that for a mixed metal compound with a surface area from 80 to 145 m 2 per gram the preferred particle size d50 is less than 343 micron, more preferably less than 296, even more preferably less than 203, most preferred less than 31 micron.
  • the compound of higher surface area of 80-145 m 2 can be manufactured using a process comprising a short residence drying step such that the resultant representative material has both small average crystal size and high surface area but also importantly and surprisingly exhibits high phosphate binding even when the material is not milled further.
  • the requirement for no muling has the advantage of reduced processing steps and avoids any hardness issues
  • a further advantage is that such material can be suitable for tabletting processes without the need for wet granulation
  • Mixed metal compounds may be synthesised by various techniques; however, it is difficult to control impurity levels of compounds when isolated in the unaged form, to a pharmaceutical grade and when prepared Al-free especially when considering that mixed metal compounds are prepared from minerals containing significant levels of trace-metal impurities some of which may be in the form of heavy metals.
  • compounds prepared from iron minerals are considerably intermeshed with other metal types as these ultimately are derived from minerals that exist in nature. Some of these metals may compete with the magnesium and iron for formation of the mixed metal compound and get locked into the hydrotalcite phase instead of forming more soluble salts which are readily washed out during the washing process.
  • the slurry is formed into a cake (with the removal of excess mother iiquor).
  • the resultant cake is then washed with water to remove excess sodium, sulphate and carbonate down to levels acceptable for the final use of the material
  • the aluminium levels of the mixed metal compound are less than
  • Chromium (Cr) levels are required to be limited to ⁇ 25 ppm according to the guideline of metal reagents for medicinal compounds CHMP/CWP/QWP/4446/00 Table 12 demonstrates that we have been able to lower the chromium levels from approximately 35 ppm to below the detection limit (less than 1 ppm),

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Abstract

There is provided a method of producing a mixed metal compound comprising at least Mg2+ and at least Fe3+ having an aluminium content of less than 10000 ppm, having an average crystal size of less than 20nm (200A) comprising the steps of: (a) combining a Mg2+ salt and a Fe3+ salt with Na2CO3 and NaOH to produce a slurry, wherein the pH of the slurry is maintained at from 9 5 to 1 1, and wherein the Na2CO3 is provided at an excess of 0 to 4,0 moles than is required to complete the reaction (b) subjecting the slurry to mixing under conditions providing a power per unit volume of 0 03 to 1,6kW/m3 (c) separating the mixed metal compound from the slurry, to obtain a crude product having a dry solid content of at least 10 wt% (d) drying the crude product either by (i) heating the crude product to a temperature of no greater than 150°C and sufficient to provide a water evaporation rate of 0.05 to 1 5 kg water per hour per kg of dry product, or (H) exposing the crude product to rapid drying at a water evaporation rate of 500 to 50000 kg water per hour per kg of dry product.

Description

METHOD
FIELD OF THE INVENTION The present invention relates to a method for producing mixed meta! compounds and to compounds prepared by these methods These compounds may have pharmaceutical activity, especially as phosphate binders The present invention further relates to novel mixed metal compounds Yet further the invention relates to pharmaceutical compositions containing the above compounds and to the pharmaceutical use of the compounds
BACKGROUND OF THE INVENTION
Hyperphosphataemia
Hyperphosphataemia is an electrolyte disturbance in which there is an abnormally elevated level of phosphate in biood Hyperphosphataemia is frequently seen in dialysis patients, as standard dialysis regimes are unable to remove the ingested phosphate load even with a low phosphate diet, and is associated with an increased risk of death and the development of vascular calcification The presence of hyperphosphataemia leads to hypocalcaemia, secondary hyperparathyroidism, reduced 1 ,25 Vit D3 and progressive metabolic bone disease Hyperphosphataemia is ultimately responsible for the increase in vascular calcification, but recent studies have also suggested that the process may additionally be influenced by 1 ,25 Vit D3 and an elevated caiciurn-phosphate product Patients who have chronically uncontrolled hyperphosphataemia develop progressively extensive soft tissue calcifications due to the deposit of Calcium/phosphate product into skin, joints, tendons, ligaments. Eye deposits of calcium/phosphate product have also been described Control of serum phosphate levels using oral phosphate binders has, therefore, become a key therapeutic target in the management of dialysis patients. These binders, taken with food, render the contained phosphate insoluble and, therefore, non-absorbable. Phosphate Binders
Historically phosphate binders included aluminium salts However, use of aluminium salts was found to result in further toxic complications due to aluminium accumulation, e.g reduction in haemoglobin production, impairment in natural repair and production of bone and possible impairment of neurological/cognitive function Renal bone disease, osteomalacia and dementia are the most significant toxicities related to the absorption of aluminium. Other aluminium compounds such as microcrystalline aluminium oxide hydroxide (boehmite) and certain hydrotaicttes were proposed for this use, such as disclosed in Ookubo et al, Journal Pharmaceutical Sciences (November 1992), 81 (1 1),
1139-1 140 However these surfer from the same drawbacks
Calcium carbonate or calcium acetate are used as phosphate binders However these suffer from the drawback that they tend to promote hypocalcaemia through the absorption of high amounts of ingested calcium and are linked to accelerated cardiovascular calcification which can cause serious side effects. Consequently, frequent monitoring of serum calcium levels is required during therapy with calcium-based phosphate binders The National Kidney Foundation Kidney Disease Quality Outcomes Initiative suggests the limited use of calcium based salts (Clinical Practice Guidelines for Bone Metabolism and Disease in Chronic Kidney Disease, Guide 5, pg 1 pt 5 5) Recent efforts, therefore, have focused on the development of phosphate binders free of calcium. More recently, lanthanum carbonate and seveiamer HCi have been used as calcium-free phosphate binders Seveiamer hydrochloride is a water-absorbing, non- absorbed hydrogel-cross-iinked polyallylamine hydrochloride but because of its structure also binds certain fat-soluble vitamins and bile acids and is therefore reported in V Autissier et al, Journal of Pharmaceutical Sciences, VoI 96, No 10, October 2007 to require large doses to be effective because it has a higher propensity for the bound phosphate to be displaced by these competing anions. A high pill burden or large tablets are often associated with poor patient compliance and this type of product is also considered relatively expensive to their calcium counter parts Seveiamer has also been associated with Gl adverse effects A J, Hutchison et al, Drugs 2003; 63 (6), 577-596
Lanthanum carbonate is a phosphate binder which has been shown to be as effective as calcium carbonate with lower incidence of hypocalcaemia. Long-term administration of lanthanum, a rare earth element, continues to raise safety concerns with regards to the potential accumulation of a rare earth metal in body tissue which can be enhanced in renal failure - Tilman B Druke, Seminars in Dialysis, Volume 20, Issue 4 page 329-332 July/August 2007
Many known inorganic preparations for treatment of hyperphosphataemia are efficient phosphate binders only over a limited pH range Moreover, particularly alkaline binders could buffer the stomach pH up to a high level at which they would not have a phosphate binding capacity.
To overcome the drawbacks associated with aluminium and also problems of efficacy over a limited pH range, WO-A-99/15189 discloses use of mixed metal compounds which are free from aluminium and which have a phosphate binding capacity of at least 30% by weight of the total weight of phosphate present, over a pH range of from 2-8.
Mixed Metal Compounds
Mixed metal compounds (mixed metal compounds) exist as so-called "Layered Double Hydroxide" (LDH) which is used to designate synthetic or natural lamellar hydroxides with two kinds of metallic cations in the main layers and interlayer domains containing anionic species. This wide family of compounds is sometimes also referred to as anionic days, by comparison with the more usual cationic clays whose interlameilar domains contain cationic species, LDHs have also been reported as hydrotalcite-like compounds by reference to one of the polytypes of the corresponding [Mg-Al] based mineral. (See "Layered Double Hydroxides: Present and Future", ed, V Rives, 2001 pub. Nova Science)
By mixed metal compound, it is meant that the atomic structure of the compound includes the cations of at least two different metals distributed uniformly throughout its structure. The term mixed metal compound does not include mixtures of crystals of two salts, where each crystal type only includes one metal cation. Mixed metal compounds are typically the result of coprecipitation from solution of different single metal compounds in contrast to a simple solid physical mixture of two different single metal salts. Mixed metal compounds as used herein include compounds of the same metal type but with the metal in two different valence states e g Fe(II) and Fe(III) as well as compounds containing more than two different metal types in one compound. The mixed metal compound may also comprise amorphous (non-crystalline) material. By the term amorphous is meant either crystalline phases which have crystallite sizes below the detection limits of x-ray diffraction techniques, or crystalline phases which have some degree of ordering, but which do not exhibit a crystalline diffraction pattern and/or true amorphous materials which exhibit short range order, but no long-range order
Mixed metal compounds provide unique challenges in using inorganic material for pharma use and in particular for phosphate binding and which are free of A!
For example, use of mixed metal compound for attaining phosphate therapeutic effects (or other pharma functional use) depends on surface processes such as physisorption (ion-exchange) and chemisorption (formation of a chemical bond) which is atypical for a drug; the therapeutic activity of most drugs are based on organic compounds which are typically more soluble
Yet further, high daily and repeated long-term (chronic) dosages are required for kidney patients but their total daily pill count requires a low tablet burden due to restricted fluid intake Consequently, high dosage of drug substance is required in final product (e g tablet) and the final product is therefore very sensitive to the properties of the mixed metal compound drug substance, unlike normal formulations. This means that the properties of the tablet, including key physical properties, and the tablet manufacturing processes, such as granulation, are often primarily influenced by the properties of the mixed metal compound active substance rather than solely by those of the excipients In order to be able to manufacture a pharmaceutical product comprising such significant quantities of mixed metal compound with the control and consistency necessary for pharmaceutical use, a means of controlling an array of opposing chemical and physical properties of the mixed metal compound is essential Therefore, considering these requirements, manufacture of such materials, particularly at large scale, presents significant problems A number of these problems are described below The ageing process (growth of crystallites) generally increases with (unintended) increased processing and handling as wel! as by the process whereby the crystallites are intentionally grown by a combination of agitation and heat-treatment of the reaction slurry before filtration Control and prevention of crystal growth can therefore be difficult
The teachings of MgAS mixed metal compounds which are manufactured in the aged form for medical applications such as antacids, do not address the problems of manufacture of unaged mixed metal compounds (on a larger scale), when the unaged form is required, for example to maintain therapeutic activity of phosphate binding Furthermore, when replacing Al for Fe we found that the mixed metal compound changes properties such as to becoming more difficult to wash and mill on a commercial scale
Al-containing mixed metal compounds that are intentionally aged to increase crystal growth have previously been manufactured on a large scale- In contrast, there appear to be no examples of large scale manufacture of unaged Al-free mixed metal compounds The method disclosed in WO99/15189 relates to Al free mixed metal compounds and includes examples of unaged and aged materials However, the products disclosed in this publication are provided at relatively small scale WO99/15189 does not address the problems of provision of product at significant scale while avoiding aging of the product The manufacture of unaged mixed metal Mg: Fe compounds (Mg. Fe defined by molar ratio hereinafter) on a large scale is problematic for a number of reasons. For example, the manufacture of unaged mixed metal Mg. Fe compounds is problematic when using conventional filtration methods. Unaged material results in a high pressure drop through the filter cake during isolation leading to !ow filtration rates or yield losses during conventional filtration Furthermore, these types of metal Mg: Fe compounds typically have small slurry particle size and as such it is difficult to carry out isolation whilst minimising ageing For example, small particles can give rise to increased processing times and/or handling issues Furthermore, too much processing and handling (e g, milling and overdrying) can present changes that are unacceptable in the final mixed metal Mg: Fe compound. In particular with such compounds, it is important to dry the material carefully as it is easy to change the surface area or internal pore volume and hence change the therapeutic activity These typical morphology properties are important characteristics affecting both the quality of the final mixed metal compound and the downstream manufacturing processes used to produce the finaf formulated pharmaceutical product containing the mixed metal compound
If processed incorrectly mixed metal compounds can become unacceptably hard This can lead to consequent issues of decreased milling rates and higher energy input to achieve a given particle size This 'knock on' effect to the processing may affect process throughput and result in overworking the material and consequential ageing
Methods for lab-scale preparations of MgFe LDH's are disclosed in art such as US 4629626; Duan X, Evans D G , Chem Commun , 2006,485-496; W Meng et al, J Chem Sci , VoI 117, No 6 November 2005, pp 635-639; Carlino, Chemistry between the sheets, Chemistry in Britain, September 1997, pp 59-62; Hashi et al, Clays and Clay Minerals (1983) pp 152-15; Raki et al, 1995, 7, 221-224; Ookubo et al, Langmuir (1993), 9, pp 1418-14221; Zhang et al Inorganic Materials Vo! 4 Mar 132-138 (1997), ReichJe, Solid States Ionics, 22, pp 135-141 (1986); Ulibarri et al, Kinetics of the Thermal Dehydration of some layered Hydrocycarbonates, Thermochimica Acta, pp 231-236 (1988); Hansen et al, Applied Clay Science 10 (1995) pp 5-19.
These methods describe lab-scale preparations only Furthermore, these materials are obtained via a process which includes an ageing step (Le a deliberate process of increasing crystal growth which is typically achieved by heating the reaction slurry over a prolonged period of time such as by a hydrothermal process). In general, the compounds of the prior art also contain substantially more than one type of anion in the interlayer region. Methods for large scale manufacturing of MgAl hydrotalcites are disclosed in art such as US-A-3650704, WO-A-2008/129034 and WO-A-93/22237 However, these describe the process for obtaining materials in the aged form resulting in a larger crystallite size (of above 200 Angstrom) and are not free of aluminium Aspects of the invention are defined in the appended claims SUMMARY ASPECTS OF THE INVENTION
!n one aspect the present invention provides a method of producing a mixed metal compound comprising
at least Mg2+ and at least Fe3÷
having an aluminium content of less than 10000 ppm,
having an average crystal size of less than 20nm (200A)
comprising the steps of.
(a) combining a Mg2+ salt and a Fe3+ salt with Na2CO3 and NaOH to produce a slurry, wherein the pH of the slurry is maintained at from 9 5 to 1 1 r and wherein the Na2CO3 is provided at an excess of 0 to 4 0 moles than is required to complete the reaction
(b) subjecting the slurry to mixing under conditions providing a power per unit volume of 0 03 to 1 6kW/m3
(c) separating the mixed metal compound from the slurry, to obtain a crude product having a dry solid content of at least 10 wt%
(d) drying the crude product either by
(i) heating the crude product to a temperature of no greater than 15O0C and sufficient to provide a water evaporation rate of 0 05 to 1 5 kg water per hour per kg of dry product, or
(ϋ) exposing the crude product to rapid drying at a water evaporation rate of 500 to 50000 kg water per hour per kg of dry product
In one aspect the present invention provides a method of producing a mixed metal compound comprising
at least Mg2+ and at least Fe3+
having an aluminium content of less than 10000 ppm,
having an average crystal size of less than 20nm (200A)
comprising the steps of.
(a) combining a Mg2+ salt and a Fe3+ salt with Na2CO3 and NaOH to produce a slurry, wherein the pH of the slurry is maintained at from 9 5 to 11 , and wherein the Na2CO3 is provided at an excess of 2 0 to 4 0 moles than is required to complete the reaction
(b) subjecting the slurry to mixing under conditions providing a power per unit volume of 0 03 to 1 6kW/m3 (c) separating the mixed metal compound from the slurry, to obtain a crude product having a dry solid content of at least 10 wt%
(d) drying the crude product either by
(i) heating the crude product to a temperature of no greater than 15O0C and sufficient to provide a water evaporation rate of 0 05 to 1 5 kg water per hour per kg of dry product, or
(ii) exposing the crude product to rapid drying at a water evaporation rate of 500 to 50000 kg water per hour per kg of dry product in one aspect the present invention provides a method of producing a mixed metal compound comprising
at least Mg2+ and at least Fe3+
having an aluminium content of less than 10000 ppm,
having an average crystal size of less than 20nm (200A),
the method comprising the step of:
(a) combining a Mg2+ salt and a Fe3+ salt with Na2CO3 and NaOH to produce a slurry, wherein the slurry is maintained to a temperature between 15 and 30 0C, and-
(i) wherein the pH of the slurry is maintained at from 9 5 to less than 9 8, and wherein the Na2CO3 is provided at an excess of greater than 1 0 to no greater than 5.0 moles than is required to complete the reaction; or (ii) wherein the pH of the slurry is maintained at from 9 5 to less than 10, and wherein the Na2CO3 is provided at an excess of greater than 1.0 to no greater than 4 0 moles than is required to complete the reaction; or (iii) wherein the pH of the slurry is maintained at from 9 5 to no greater than
10 1, and wherein the Na2COa is provided at an excess of greater than 1 0 to no greater than 2 7 moles than is required to complete the reaction; or (iv) wherein the pH of the slurry is maintained at from 9 5 to 10 5, and wherein the Na2CO3 is provided at an excess of from greater than 1 0 to no greater than 2.0 moles than is required to complete the reaction; or
(v) wherein the pH of the slurry is maintained at from greater than 9 5 to no greater than 11 , and wherein the Na2CO3 is provided at an excess of from 0 0 to no greater than 1 0 moles than is required to complete the reaction;
or the method comprising the step of:
(b) combining a Mg2+ salt and a Fe3+ salt with Na2CO3 and NaOH to produce a slurry, wherein the slurry is maintained to a temperature from 30 to 60 0C, and- (i) wherein the pH of the slurry is maintained at from greater than 9 5 to (ess than 1 1 , and wherein the Na2CO3 is provided at an excess of greater than O to less than 2 moies than is required to complete the reaction; or (ii) wherein the pH of the slurry is maintained at from greater than 9 5 to less than 10.5, and wherein the Na2CO3 is provided at an excess of greater than O to iess than 2 7 moles than is required to complete the reaction; or (iii) wherein the pH of the slurry is maintained at from greater than 9.5 to less than 10, and wherein the Na2CO3 is provided at an excess of greater than O to less than 4 moles than is required to complete the reaction in one aspect the present invention provides a method of producing a mixed metal compound comprising
at least Mg2+ and at least Fe3+
having an aluminium content of less than 10000 ppmr
having an average crystal size of less than 20nm (200A),
the method comprising the step of:
(a) combining a Mg2+ salt and a Fe3+ salt with Na2CO3 and NaOH to produce a slurry, wherein the slurry is maintained to a temperature between 15 and 30 0C, and:
(i) wherein the pH of the slurry is maintained at from 9.5 to less than 9 8, and wherein the Na2CO3 is provided at an excess of greater than 2 0 to no greater than 4 0 moles than is required to complete the reaction; or (it) wherein the pH of the slurry is maintained at from 9.5 to less than 10,3, and wherein the Na2CO3 is provided at an excess of greater than 2 0 to less than 4 0 moles than is required to complete the reaction; or
(iii) wherein the pH of the slurry is maintained at from greater than 9,8 to no greater than 10.5, and wherein the Na2CO3 is provided at an excess of greater than 1.0 to less than 2.7 moles than is required to complete the reaction, or
(iv) wherein the pH of the slurry is maintained at greater than 9 8 to less than
10.3, and wherein the Na2CO3 is provided at an excess of from 1.0 to less than 4 0 moles than is required to complete the reaction,
or the method comprising the step of:
(b) combining a Mg2+ salt and a Fe3+ salt with Na2COa and NaOH to produce a slurry, wherein the slurry is maintained to a temperature from 30 to 65 0C, and: (i) wherein the pH of the slurry is maintained at from 9,5 to no greater than 10 5, and wherein the Na2CO3 is provided at an excess of greater than 0 to less than 2 7 moles than is required to complete the reaction; or (ii) wherein the pH of the slurry is maintained at from 9 5 to iess than 10, and wherein the Na2CO3 is provided at an excess of greater than 0 to iess than 4 moles than is required to complete the reaction.
In one aspect the present invention provides a mixed meta! compound comprising at least Mg2+ and at least Fe3+
having an aluminium content of less than 10000 ppm,
having an average crystal size of less than 20nm (200A), wherein the compound is obtained or obtainable by a method comprising the steps of
(a) combining a Mg2+ salt and a Fe3+ salt with Na2CO3 and NaOH to produce a slurry, wherein the pH of the slurry is maintained at from 9.5 to 11 , and wherein the Na2CO3 is provided at an excess of 0 to 4 0 moles than is required to complete the reaction
(b) subjecting the slurry to mixing under conditions providing a power per unit volume of 0 03 to 1 6kW/m3
(c) separating the mixed metal compound from the slurry, to obtain a crude product having a dry solid content of at ieast 10 wt%
(d) drying the crude product either by
(i) heating the crude product to a temperature of no greater than 15O0C and sufficient to provide a water evaporation rate of 0 05 to 1 5 kg water per hour per kg of dry product, or
(ii) exposing the crude product to rapid drying at a water evaporation rate of
500 to 50000 kg water per hour per kg of dry product. in one aspect the present invention provides a mixed metal compound comprising at least Mg2+ and at least Fe3+
having an aluminium content of less than 10000 ppm,
having an average crystal size of less than 20nm (200A), wherein the compound is obtained or obtainable by a method comprising the steps of:
(a) combining a Mg2+ salt and a Fe3+ salt with Na2CO3 and NaOH to produce a slurry, wherein the pH of the slurry is maintained at from 9.5 to 11 , and wherein the Na2CO3 is provided at an excess of 2.0 to 4 0 moles than is required to complete the reaction (b) subjecting the slurry to mixing under conditions providing a power per unit volume of 0 03 to 1 6kW/m3
(c) separating the mixed metai compound from the slurry, to obtain a crude product having a dry solid content of at least 10 wt%
(d) drying the crude product either by
(i) heating the crude product to a temperature of no greater than 15O0C and sufficient to provide a water evaporation rate of 0 05 to 1 5 kg water per hour per kg of dry product, or
(ii) exposing the crude product to rapid drying at a water evaporation rate of 500 to 50000 kg water per hour per kg of dry product
In one aspect the present invention provides a mixed metal compound comprising at least Mg2+ and at least Fe3+
having an aluminium content of less than 10000 ppm,
having an average crystal size of less than 20nm (200A), wherein the compound is obtained or obtainable by a method comprising the steps of.
(a) combining a IvIg2+ salt and a Fe3+ salt with NaaCO3 and NaOH to produce a slurry, wherein the slurry is maintained to a temperature between 15 and 30 DC, and:
(i) wherein the pH of the slurry is maintained at from 9 5 to less than 9 8, and wherein the NaaCO3 is provided at an excess of greater than 1 0 to no greater than 5 0 moles than is required to complete the reaction; or (ii) wherein the pH of the slurry is maintained at from 9.5 to less than 10, and wherein the Na2CO3 is provided at an excess of greater than 1.0 to no greater than 4 0 moles than is required to complete the reaction, or
(iii) wherein the pH of the slurry is maintained at from 9 5 to no greater than 10.1 , and wherein the Na2CO3 is provided at an excess of greater than 1 0 to no greater than 2 7 moles than is required to complete the reaction; or (iv) wherein the pH of the slurry is maintained at from 9 5 to 10 5, and wherein the Na2CO3 is provided at an excess of from greater than 1 0 to no greater than 2,0 moles than is required to complete the reaction; or (v) wherein the pH of the slurry is maintained at from greater than 9 5 to no greater than 1 1 , and wherein the Na2CO3 is provided at an excess of from 0.0 to no greater than 1 0 moles than is required to complete the reaction or by the method comprising the step of: (b) combining a Mg2* salt and a Fe3* salt with Na2CO3 and NaOH to produce a slurry, wherein the slurry is maintained to a temperature from 30 to 60 0C1 and'
(i) wherein the pH of the slurry is maintained at from greater than 9 5 to less than 11 , and wherein the Na2CO3 is provided at an excess of greater than 0 to less than 2 moles than is required to complete the reaction; or
(ii) wherein the pH of the slurry is maintained at from greater than 9 5 to less than 10 5, and wherein the Na2COs is provided at an excess of greater than 0 to less than 2 7 moles than is required to complete the reaction; or (iii) wherein the pH of the slurry is maintained at from greater than 9 5 to less than 10, and wherein the Na2CO3 is provided at an excess of greater than 0 to less than 4 moles than is required to complete the reaction
In one aspect the present invention provides a mixed metal compound comprising at least Mg2+ and at least Fe3+
having an aluminium content of less than 10000 ppm,
having an average crystal size of less than 20nm (200A), wherein the compound is obtained or obtainable by a method comprising the steps of
(a) combining a Mg24 salt and a Fe3+ salt with Na2CO3 and NaOH to produce a slurry, wherein the slurry is maintained to a temperature between 15 and 30 0C, and:
(i) wherein the pH of the slurry is maintained at from 9 5 to less than 9 8, and wherein the Na2CO3 is provided at an excess of greater than 2 0 to no greater than 4.0 moles than is required to complete the reaction; or (ii) wherein the pH of the slurry is maintained at from 9,5 to less than 10 3, and wherein the NSaCO3 is provided at an excess of greater than 2 0 to less than 4.0 moles than is required to complete the reaction; or
(iii) wherein the pH of the slurry is maintained at from greater than 9.8 to no greater than 10 5, and wherein the Na2COa is provided at an excess of greater than 1 ,0 to less than 2 7 moles than is required to complete the reaction; or
(iv) wherein the pH of the slurry is maintained at greater than 9 8 to less than 10.3, and wherein the Na2CO3 is provided at an excess of from 1 0 to less than 4 0 moles than is required to complete the reaction;
or by the method comprising the step of
(b) combining a Mg2+ salt and a Fe3+ salt with Na2CO3 and NaOH to produce a slurry, wherein the slurry is maintained to a temperature from 30 to 65 0C, and" (i) wherein the pH of the slurry is maintained at from 9 5 to no greater than 10 5, and wherein the Na2CC>3 is provided at an excess of greater than 0 to iess than 2 7 moles than is required to complete the reaction; or (ii) wherein the pH of the slurry is maintained at from 9 5 to iess than 1O1 and wherein the Na2CO3 is provided at an excess of greater than 0 to less than 4 moles than is required to complete the reaction
In one aspect the present invention provides a mixed metal compound comprising at least Mg2+ and at least Fe3+,
wherein
the molar ratio of Mg2+ to Fe3+ is 2 5.1 to 1 5: 1 ,
the mixed metal compound has an aluminium content of less than 10000 ppm, the average crystal size of the mixed metal compound is from 10 to 20πm (100 to 2QθA), and the d50 average particle size of the mixed metal compound is less than 300 μm
In one aspect the present invention provides a mixed metal compound comprising at least Mg2+ and at ieast Fe3+,
wherein
the molar ratio of Mg2+ to Fe3+ is 2 5:1 to 1 5:1 ,
the mixed metal compound has an aluminium content of less than 10000 ppm, the average crystal size of the mixed metal compound is from 10 to 20nm (100 to 200A), and the water pore volume of the mixed metal compound is from 0.25 to 0 7 cm3/g of mixed metal compound !n one aspect the present invention provides a mixed metal compound comprising at ieast Mg2+ and at least Fe3+,
wherein
the molar ratio of Mg2+ to Fe3+ is 2 5:1 to 1 5: 1,
the mixed metal compound has an aluminium content of iess than 10000 ppm, the average crystal size of the mixed metal compound is from 10 to 20nm (100 to 200A), and the interiayer sulphate content of the compound is from 1.8 to 5 wt%
In one aspect the present invention provides a mixed metal compound comprising at least Mg2+ and at least Fe3+,
wherein
the molar ratio of Mg2+ to Fe3+ is 2 5: 1 to 1 5:1 r the mixed metal compound has an aluminium content of less than 10000 ppm, the average crystal size of the mixed metal compound is from 10 to 20nm (100 to 200A), and the interlayer sulphate content of the compound is from 1 8 to 3 2 wt%. In one aspect the present invention provides a mixed metal compound comprising at least Mg2+ and at ieast Fe3+,
wherein
the molar ratio of Mg2+ to Fe3+ is 2 5:1 to 1 5-1 ,
the mixed metal compound has an aluminium content of less than 10000 ppm, the average crystal size of the mixed metal compound is less than 20nm (20ϋA), and the interlayer sulphate content of the compound is from 1 8 to 5 wt%.
In one aspect the present invention provides a mixed metal compound comprising at least Mg2+ and at least Fe3+,
wherein
the molar ratio of Mg2+ to Fe3+ is 2 5:1 to 1.5 1 ,
the mixed metal compound has an aluminium content of less than 10000 ppm, the average crystal size of the mixed metal compound is less than 20nm (200A)1 and the interlayer sulphate content of the compound is from 1 8 to 3 2 wt%
In one aspect the present invention provides a mixed metal compound comprising at least Mg2+ and at least Fe3+,
wherein
the molar ratio of Mg2+ to Fe3+ is 2 5:1 to 1 5 1,
the mixed metal compound has an aluminium content of less than 10000 ppm, the average crystal size of the mixed metal compound is less than 20πm (200A), and the surface area is from 80 to 145m2 per gram of compound,
In one aspect the present invention provides a mixed metal compound comprising at least Mg2+ and at least Fe3+,
wherein
the molar ratio of Mg2+ to Fe3+ is 2 5-1 to 1.5:1 ,
the mixed metal compound has an aluminium content of less than 10000 ppm, the average crystal size of the mixed metal compound is from 10 to 20nm (100 to 20ϋA), the surface area is from 40 to 80 m2 per gram of compound. In one aspect the present invention provides a mixed metal compound as described herein for use as a medicament
In one aspect the present invention provides a mixed metal compound as described herein for binding phosphate
In one aspect the present invention provides a mixed metal compound as described herein for use in the treatment of hyperphosphataemia !n one aspect the present invention provides a pharmaceutical composition comprising a mixed metal compound as described herein and optionally one or more pharmaceutically acceptable adjuvants, excipients, diluents or carriers
Some Advantages
The present method provides a process which may be operated on a large scale to provide for a pharmaceutical phosphate binding drug of consistent composition which is stable upon storage and can be easily formulated and/or packaged. Moreover, the present method provides for control of key properties such as average crystal size, particle size, surface area, other morphology parameters (such as pore volume) and degree of hydration - ail of which are important for such manufacture
A!-free mixed metal compounds containing Fe and Mg typically have a clay-like structure This presents limitations in view of the difficult filtration of such products which in turn affect the viability of a controlled process
The present method provides a process which allows for manufacture of a consistent 'Al- free1 mixed metal compounds suitable for use in final product formulations (e g tablet formulations etc) The therapeutic effect of the final products and the ability to process the mixed metal compounds into a final product consistently, depend on the physical (i e particle- and crystallite-size) and chemical (i e composition) properties of the mixed metal compound The present process provides a method for a consistent manufacture of pharmaceutical-grade 'Al-free' mixed metal compounds with consistent particle- and crystallite-size In one aspect the present invention provides a mixed metal compound comprising at least Mg2+ and at ieast Fe3+, wherein the molar ratio of Mg2+ to Fe3+ is 2 5i to 1 5:1 , the mixed metal compound has an aluminium content of less than 10000 ppm, the average crystal size of the mixed metal compound is from 10 to 20nm (100 to 200A)1 and the interiayer sulphate content of the compound is from 1 8 to 5 wt% (such as from 1„8 to 3.2
%).
For mixed metal compounds, maintaining the target metal molar ratio (Mg: Fe) during the reaction whilst meeting the above criteria is difficult as this is affected by the way the material is processed. We found that correct stoichiometry is not only determined by the correct ratios of the starting materials but also by pH for the reaction; i e. when a pH is below pH 9,5 incomplete precipitation of magnesium may occur and too high a pH (i.e. above pH 1 1) risks loss of iron Mixed metal compounds can have more than one type of anion within the interiayer region. This can introduce impurities which are undesirable when considering pharma use and we found can also affect therapeutic activity (of phosphate binding). We have also found, surprisingly, that the type and amount of anions present in the interiayer region has a marked effect on the time taken to complete separation and washing of the unaged product, particularly for commercial scale manufacture. For example, we have found that at low (below 1 8 %wt) interiayer sulphate levels, separation and washing times increase significantly
We found that when the amount of interiayer sulphate is maintained from 1 ,8 to 5 wt% (such as from 1 8 to 3 2 wt%) phosphate binding of more than 0 60 mmol phosphate/g compound can be obtained whilst maintaining low filtration and wash times.
The combination of process parameters of the present method provides for the preparation of mixed metal compounds which have controlled sulphate (SO4) levels in the interiayer region.
Soluble SO4 in the form of Na2SO4 salt can be readily removed by washing whereas the interiayer sulphate cannot be removed by washing with water We found that the interiayer sulphate could be reduced without necessarily increasing the filtration and wash times by reslurrying the dried compound in a solution containing carbonate enabling ion-exchange; however, this meant an additional reaction, isolation and drying step and generally lead to a decrease in phosphate binding Furthermore, this route would result in a longer overall time to manufacture. This route to control interlayer sulphate is therefore less preferred. Alternatively, the interlayer sulphate may be reduced by washing or reslurrying the filtercake after isolation with a solution containing carbonate instead of water Again this would lead to an additional process step and is less preferred
We found that by control of the process parameters as described herein, one may prepare a mixed metal compound having low levels of impurities, and in particular heavy metal impurities, without the need to perform purification to remove such impurities The present invention may provide a process for preparing a mixed metal compound having a lead content of less than 1 ppm and/or a chromium content of less than 30 ppm and/or a total heavy metai content of less than 10 ppm and/or a sodium content expressed as Na2O of less than 0,5 wt%. in one aspect the mixed metal compound has a total heavy meta! content of less than 25 ppm, preferably less than 10 ppm For example the present invention may provide a process for preparing a mixed metal compound having a total heavy metal content of less than 15 ppm, a !ead content less than 10 ppm, a chromium level less than 35 ppm and a sodium content (expressed as Na2O) of less than 1 wt%,
Heavy metals content as referred to herein are the group consisting of As, Cd, Pb, Hg, Sb, Mo and Cu Thus, reference to total heavy metal content will be understood to mean the combined content of As, Cd, Pb, Hg, Sb, Mo and Cu. WO99/15189 teaches the preparation of a slurry at pH above 10 using a 5 mole Na2CO3: 12 mole NaOH ratio which equates to an excess of 4 mole NazCOa than required to complete the reaction equation:
4MgSO4 + Fe2(SO4J3 + 12 NaOH + 5Na2CO3 ->
Mg4Fe2(OH)12 CO3..nH2O + 7Na2SO4 + 4Na2CO3
We have found that this excess of 4 mole Na2CO3 is not preferred, especially when precipitated at a pH of more than 10 and at room temperature- We found that this combination results in reduced solubility of the carbonate in the reactant solution at the desired reaction temperatures, provides poor filtration and wash times. We have found that when preparing unaged material of 2:1 Mg. Fe molar ratio according to method of WO99/15189 that this material was more difficult to separate and wash when manufactured at scale whilst maintaining good phosphate binding. This resulted in loss of batches as a result of material being out of specification Sodium carbonate not only provides the carbonate for the anion-exchange sites, but also acts as a pH buffer which assists pH control during precipitation. The ability to maintain an accurate precipitation pH is considerably increased when Na2CO3 is present
However, we have also found that the filtration rate significantly increases when Na2CO3 is reduced from a 2 7 mole excess to zero excess A high filtration rate is advantageous when seeking to manufacture an unaged form of the Mg Fe mixed metal compounds.
Such materials can be difficult to filter Also decreasing the Na2CO3 further, such as below the 2 7 mole excess, may result in less precise pH control as well as increasing the level of sulphate anions present in the interlayer region As a consequence of the above, we have identified that there is a complex interrelationship between pH, mole excess Na2CO3 and the temperature at which the slurry is maintained, alt of which are important to maintain good phosphate binding and filtration and or wash times In particular we have determined that in order to obtain phosphate binding above O 60 rnmoi phosphate/g compound and maintain good filtration and wash time it is preferred to produce a slurry, wherein a temperature is maintained between 15 and 30 0C
(i) wherein the pH of the slurry is maintained at from 9 5 to less than 9 8, and wherein the NaaCOs is provided at an excess of greater than 1 0 to no greater than 5.0 moles than is required to complete the reaction; or
(ii) wherein the pH of the slurry is maintained at from 9 5 to less than 10, and wherein the Na2CO3 is provided at an excess of greater than 1 0 to no greater than 4 0 moles than is required to complete the reaction; or
(ϋi) wherein the pH of the slurry is maintained at from 9 5 to no greater than 10 1 , and wherein the Na2CO3 is provided at an excess of greater than 1.0 to no greater than 2.7 moles than is required to complete the reaction; or (iv) wherein the pH of the slurry is maintained at from 9 5 to 10 5, and wherein the Na2CO3 is provided at an excess of from greater than 1 0 to no greater than 2 0 moles than is required to complete the reaction; or (v) wherein the pH of the slurry is maintained at from greater than 9 5 to no greater than 11 , and wherein the Na2CO3 is provided at an excess of from 0 0 to no greater than 1 0 moles than is required to complete the reaction Alternatively, a Mg2+ salt and a Fe3+ salt can be combined with Na2CO3 and NaOH to produce a slurry, wherein the slurry is maintained to a temperature from 30 to 60 0C
(i) wherein the pH of the slurry is maintained at from greater than 9 5 to less than 1 1 , and wherein the Na2CO3 is provided at an excess of greater than 0 to less than 2 moles than is required to complete the reaction, or
(ii) wherein the pH of the slurry is maintained at from greater than 9 5 to less than 10 5, and wherein the Na2CO3 is provided at an excess of greater than O to less than 2 7 moles than is required to complete the reaction, or (iii) wherein the pH of the slurry is maintained at from greater than 9.5 to less than 10, and wherein the Na2COa is provided at an excess of greater than O to less than 4 moles than is required to complete the reaction
Furthermore, we have found that in order to avoid the presence of additional crystalline phases in the compound (i e phases other than hydrotalcite-type as detected by powder X-ray Diffraction) It is necessary to wash the product to such an extent that the unbound sulphate (SO4) i e in form of sodium sulphate (Na2SO4) is maintained below 1 5 wt% (when expressed as Na2SO4) and preferably less than 1 wt% (when expressed as SO4) This conversely can only be achieved when a small amount of the interlayer sulphate is maintained such as to enable effective filtration and washing at commercial scale
The present method is a co-precipitation process Such processes encourage the formation of different crystalline phases in addition to the hydrotalcite phase For use as an active in pharmaceutical formulations, there is the requirement to be able to identify and control the phase of interest. The present method provides for the preparation of mixed metal compounds which contain less of (or are substantially free of) any other crystalline phases as determined by the absence of XRD diffraction lines except those attributed to a hydrotalcite phase. The hydrotalcite phase had the following diffraction X- ray diffraction analysis. dA ('d1 spacings) 7 74*, 3 86*, 3.20, 2.62*, 2 33*, 1,97*, 1 76, 1 64, 1 55*, 1 52*, 1.48, 1 44*, 1.40, of which the peaks marked * are the eight most intense peaks typically seen in the unaged samples The remaining five peaks are only resolved in more crystalline samples, typically as a result of ageing
In summary, we have found that a total process of production (from reaction to drying) is provided such as to prevent growth of the crystallite size (above average crystal size 200 A) in order to maintain the phosphate binding activity without significantly hindering the process of isolation and washing of the compound This was achieved by careful control of process conditions and a specific selection of the same such as by controlling interiayer sulphate from 1 8 to 5 wt% (such as from 1.8 to 3.2 wt%) which in turn can be controlled via selection of excess Na^COa , reaction pH and reaction slurry temperature In one aspect the present invention provides a mixed metal compound comprising at least Mg2+ and at least Fe3+, wherein the molar ratio of Mg2+ to Fe3+ is 1 5:1 to 2 5:1 , the mixed metal compound has an aluminium content of less than 10000 ppm, the average crystal size of the mixed metal compound is from 10 to 20nm (100 to 200 A)1 and the d50 average particle size of the mixed metal compound is less than 300 μm We have found surprisingly that this unaged compound with such average crystal size range and with milled particle size less than 300 microns, has the advantages of good, controlled phosphate binding (above 0 60 mmol phosphate/g compound) whilst maintaining low magnesium release (less than 0 2 mmol magnestum/g compound) Above 300 micron particle size we have found that the phosphate binding decreases markedly and magnesium release increases to above 0 2 mmol rnagnesium/g compound
We have found that an average crystal size of the mixed metal compound of less than 20nm (200A) and high surface area (80-145 m2/g) can be manufactured using a process comprising a short residence drying step such that the resultant material has both small average crystal size and high surface area but also importantly has a higher phosphate binding capacity as well as a lower magnesium release when compared at similar d50 average particle size to that of the low surface area (40-80 m2/g) materia!; even when the material is not milled further. The requirement for no milling has the advantage of reduced processing steps. A further advantage is that such material can be suitable for tabletting processes without the need for wet granulation A further advantage is that material manufactured via the short residence route may be exposed to temperatures above 150 0C because the residence time (less than 5 minutes) of the product in the dryer is generally too short to enable any decomposition of the compound. The mixed metal compound having an average crystal size of from 10 to 20nm (100 to 200A) and surface area 40-80 m2/g has the benefit of good stability in particular phosphate binding, on storage This product has the additional benefit of providing a smaller tablet size (i e less than 500 mm3 for 500 mg compound) thereby improving tablet pill burden; a prevalent issue within the treatment of rena! patients. The material of surface area 40-80 m2/g which required micronisation can be manufactured at commercial scale, including milling of the material, with minimal impact on aging of the material as reflected in maintaining a small average crystal size of below 200 A If the crystallite size is less than 100 A it presents difficulties in milling to small particle size of for example, problems with trace metal impurities, muling rate and decomposition of the product and over-drying of the product Furthermore an additional surprising benefit is that such materials also exhibit no significant reduction in the uptake rate of phosphate, despite the lower surface areas This facet can be important when considering such materials for pharmaceutical applications in which the binding of phosphate needs to be rapid such as renal care We have found that the material described above bind 80% phosphate within 10 minutes (Test Method 3)
As for the product of 10 to 20nm (100 to 2OθA) average crystal size and 40-80 m2/g surface area , the product of low surface area and low pore volume by water from 0.3 to 0 65 cm3/g has the additional benefit of providing a smaller tablet size (i.e. less than 500 mm3 for 500 mg compound) thereby improving tablet pill burden; a prevalent issues within the treatment of renal patients. Furthermore a higher density materia! is more suitable for the manufacture by wet granulation of compact tablets.
If product is dried to less than 85 wt% dry solid content storage problems may be observed because of water-desorption If product is dried to less than 80 wt% dry solid content, milling may be problematic If product is dried to more than 99 wt% the phosphate binding may be reduced If product is too dry storage problems may also be observed because of water-adsorption. Therefore, in one embodiment, the product is dried such that it has 80 wt% to 99 wt% dry solid content, preferably 85 wt% to 99 wt% In one aspect the present invention provides a mixed metal compound comprising at least Mg2+ and at least Fe3+, wherein the molar ratio of Mg2+ to Fe3+ is 1.5: 1 to 2 5.1 , the mixed metal compound has an aluminium content of less than 10000 ppm, the average crystal size of the mixed metal compound is from 10 to 20nm (100 to 200A), and the water pore volume of the mixed metal compound is from 0.3 to 0 65 cm3/g of mixed metal compound Surprisingly we have found that this low pore volume compound has the advantage of good phosphate binding that is essentially unchanged upon storage over periods of up to years, making it viable as a pharmaceutically active material It may be expected typically that significantly higher pore volumes would be required to attain such stability
As used herein, the term 'water pore volume' refers to the pore volume as determined in accordance with Test Method 15
For ease of reference, these and further aspects of the present invention are now discussed under appropriate section headings However, the teachings under each section may be combined and are not necessarily limited to each particular section
PREFERRED ASPECTS
As discussed herein the present invention provides a method of producing a mixed rnetai compound comprising
at least Mg2+ and at least Fe3+
having an aluminium content of less than 10000 ppm,
having an average crystal size of less than 20nrn (200A)
comprising the steps of:
(a) combining a Mg2+ salt and a Fe3+ salt with Na^COa and NaOH to produce a slurry, wherein the pH of the slurry is maintained at from 9.5 to 11 , and wherein the Na2CO3 is provided at an excess of 0 to 4 0 moles than is required to complete the reaction
(b) subjecting the slurry to mixing under conditions providing a power per unit volume of 0 03 to 1 6 kW/m3
(c) separating the mixed metal compound from the slurry, to obtain a crude product having a dry solid content of at least 10 wt%
(d) drying the crude product either by
(i) heating the crude product to a temperature of no greater than 1500C and sufficient to provide a water evaporation rate of 0,05 to 1 5 kg water per hour per kg of dry product, or
(ii) exposing the crude product to rapid drying at a water evaporation rate of 500 to 50000 kg water per hour per kg of dry product it will be understood by one skilled in the art that by "average crystal size" it is meant the crystal size as measured in accordance with Test Method 2
In one preferred aspect, in step (a) a Mg2+ salt and a Fe3+ salt are combined with Na2CO3 and NaOH to produce a slurry, wherein the pH of the slurry is maintained at from 9 5 to 10 5 Preferably the pH of the slurry is maintained at from 9 5 to less than 10 1 Preferably the pH of the slurry is maintained at from 9 5 to less than 10. Preferably the pH of the slurry is maintained at from 9 5 to Sess than 9.8, Preferably the pH of the slurry is maintained at from 9 6 to 9 9 More preferably the pH of the slurry is maintained at approximately 9 8 In one preferred aspect, in step (a) a Mg2+ salt and a Fe3+ salt are combined with Na2CO3 and NaOH to produce a slurry, wherein the Na2CO3 is provided at an excess from 2 O to less than 4 O moles, preferably at an excess from 2 7 to less than 4 O moles, preferably at an excess from 2.7 to less than 3 2 moles, preferably at an excess from 2.7 to less than 3.0 moles More preferably the Na2CO3 is maintained at an excess of approximately 2.7 moles
In one preferred aspect, in step (a) a Mg2+ salt and a Fe3* salt are combined with Na2CO3 and NaOH to produce a slurry, wherein the slurry is maintained to a temperature between 15 and 30 0C
(i) wherein the pH of the slurry is maintained at from 9 5 to less than 9.8, and wherein the Na2CO3 is provided at an excess of greater than 1.0 to no greater than 5 O moles than is required to complete the reaction; or (ϋ) wherein the pH of the slurry is maintained at from 9 5 to less than 10, and wherein the Na2CO3 is provided at an excess of greater than 1 O to no greater than 4.0 moles than is required to complete the reaction; or
(iii) wherein the pH of the slurry is maintained at from 9 5 to no greater than 10~1 , and wherein the Na2CO3 is provided at an excess of greater than 1 O to no greater than 2.7 moles than is required to complete the reaction; or (iv) wherein the pH of the slurry is maintained at from 9.5 to 10.5, and wherein the Na2CO3 is provided at an excess of from greater than 1.0 to no greater than 2 O moles than is required to complete the reaction, or (v) wherein the pH of the slurry is maintained at from greater than 9 5 to no greater than 1 1 , and wherein the Na2CO3 is provided at an excess of from 0.0 to no greater than 1 O moles than is required to complete the reaction. in one preferred aspect, in step (a) a Mg2+ salt and a Fe3+ salt are combined with Na2CO3 and NaOH to produce a slurry, wherein the slurry is maintained to a temperature between 15 and 30 0C
i) wherein the pH of the slurry is maintained at from 9.5 to less than 9 8, and wherein the Na2CO3 is provided at an excess of greater than 2.0 to no greater than 4.0 moles than is required to complete the reaction; or (ii) wherein the pH of the slurry is maintained at from 9 5 to less than 10 3, and wherein the Na2CO3 is provided at an excess of greater than 2 0 to less than 4 0 moles than is required to complete the reaction; or
(iii) wherein the pH of the slurry is maintained at from greater than 9 8 to no greater than 10 5, and wherein the Na2CO3 is provided at an excess of greater than 1 0 to less than 2 7 moles than is required to complete the reaction; or
(iv) wherein the pH of the slurry is maintained at greater than 9 8 to less than 10 3, and wherein the Na3CO3 is provided at an excess of from 1 0 to less than 4 0 moles than is required to complete the reaction;
In one preferred aspect, in step (a) a Mg2+ salt and a Fe3+ salt are combined with Na2CO3 and NaOH to produce a slurry, wherein the slurry is maintained to a temperature from 30 to 60 °C
(i) wherein the pH of the slurry is maintained at from greater than 9 5 to less than 11 , and wherein the Na2CO3 is provided at an excess of greater than 0 to less than 2 moles than is required to complete the reaction; or (ϋ) wherein the pH of the slurry is maintained at from greater than 9 5 to less than 10 5, and wherein the Na2CO3 is provided at an excess of greater than 0 to less than 2.7 moles than is required to complete the reaction; or
(iii) wherein the pH of the slurry is maintained at from greater than 9 5 to less than 10, and wherein the Na2CO3 is provided at an excess of greater than 0 to less than 4 moles than is required to complete the reaction In one preferred aspect, in step (a) a Mg2+ salt and a Fe3+ salt are combined with Na2CO3 and NaOH to produce a slurry, wherein the slurry is maintained to a temperature from 30 to 65 °C
(i) wherein the pH of the slurry is maintained at from 9.5 to no greater than 10 5, and wherein the Na2CO3 is provided at an excess of greater than 0 to less than 2 7 moles than is required to complete the reaction; or
(ii) wherein the pH of the slurry is maintained at from 9 5 to less than 10, and wherein the Na2CO3 is provided at an excess of greater than 0 to less than 4 moles than is required to complete the reaction In one preferred aspect, in step (b) the slurry is subjected to mixing under conditions providing a power per unit volume of 0 03 to 1 6kW/m3 In one preferred aspect, in step (b) the slurry is subjected to mixing under conditions providing a power per unit volume of 0.03 to 0.5kW/m3 In one preferred aspect, in step (b) the slurry is subjected to mixing under conditions providing a power per unit volume of 0.05 to 0 5kW/m3 In one preferred aspect, in step (b) the slurry is controlled to a d50 particle size distribution (psd) of at least 40 μm. Preferably, the slurry is controlled to a d50 psd of greater than 40 μm, Preferably, the slurry is controlled to a d50 psd of at least 50 μm Preferably, the slurry is controlled to a d50 psd of at least 60 μm. More preferably, the slurry is controiled to a d50 psd of at least 70 μm Preferably, the slurry is controlled to a d50 psd of greater than 70 μm. The d50 psd of the slurry is as measured in accordance with Test Method 9 herein
As used herein, the term 'particle size distribution' refers to the d50 or average particle size distribution as determined in accordance with Test Method 24 D50 refers to the 50th percentile of that Test Method
In one preferred aspect, in step (b) the slurry is controlled to a d50 psd of at least 40 μm after the addition of the reactants and after an initial hold time of 30 minutes to attain the optimum particle size distribution, Preferably, the slurry is controiled to a d50 psd of at least 50 μm after the addition of the reactants and after an initial hold time of 30 minutes. Preferably, the slurry is controlled to a d50 psd of at least 60 μm after the addition of the reactants and after an initial hoid time of 30 minutes More preferably, the slurry is controlled to a d50 psd of at least 70 μm after the addition of the reactants and after an initial hold time of 30 minutes
In one preferred aspect, the hold time of slurry before isolation, such as before step (c), is less than 16 hours, preferably less than 12 hours. Preferably, the hold time is more than 30 minutes. In one preferred aspect, the hold time of slurry before isolation, such as before step (c), from 30 minutes to 16 hours. In one preferred aspect, the hold time of slurry before isolation, such as before step (c), from 30 minutes to 12 hours. If hold time increases to more than 16 hours the crystallite size may increase and/or particle size change,
In step (c) of the present method, the mixed metal compound is separated from the slurry, to obtain a crude product having a dry solid content of at least 10 wt%. Preferably the mixed metal compound is separated from the slurry, to obtain a crude product having a dry solid content of at least 15 wt% More preferably the mixed metal compound is separated from the slurry, to obtain a crude product having a dry solid content of at ieast 20 wt% in step (d) of the present method the crude product is dried either by
(i) heating the crude product to a temperature of no greater than 1500C and sufficient to provide a water evaporation rate of 0 05 to 1 5 kg water per hour per kg of dry product, or (ϋ) exposing the crude product to rapid drying at a water evaporation rate of 500 to 50000 kg water per hour per kg of dry product
It will be understood by one skilled in the art that reference to "heating the crude product to a temperature of no greater than X0C" refers to the heating the product such that the bulk temperature of the product is no greater than X0C It will be understood that the temperature to which the product is exposed, for example a drum temperature in the case of drum drying, or the temperature of the shell of the product may be greater than X0C when the bulk temperature of the product is X0C
It will be understood by one skilled in the art that reference to a water evaporation rate at a rate of kg water per hour per kg of dry product, is to be measured in accordance with Test Method 18
In one preferred aspect, step d(i) is followed, that is in step (d) the crude product is dried by heating the crude product to a temperature of no greater than 1500C and sufficient to provide a water evaporation rate of 0 05 to 1 5 kg water per hour per kg of dry product
In one preferred aspect, step d(ii) is followed, that is in step (d) the crude product is dried by exposing the crude product to flash drying or spray drying at a water evaporation rate of 500 to 50000 kg water per hour per kg of dry product Preferably when step d(i) is followed, the crude product is dried by heating the crude product to a temperature of no greater than 15O0C and sufficient to provide a water evaporation rate of 0 05 to 1 kg water per hour per kg of dry product, more preferably a water evaporation rate of 0 05 to 0 5 kg water per hour per kg of dry product, even more preferably a water evaporation rate of 0 09 to 0 5 kg water per hour per kg of dry product, most preferred a water evaporation rate of 0 09 to 0 38 kg water per hour per kg of dry product Preferably when step d(i) is followed, the crude product is dried by heating the crude product to a temperature of no greater than 150 0C, such as no greater than 140 0C, such as no greater than 130 0C, such as no greater than 120 0C, such as no greater than 1 10 0C, such as no greater than 100 0C, such as no greater than 90 0C, such as from 60 to 150 0C, such as from 70 to 150 0C, such as from 60 to 140 0C, such as from 70 to 140 0C, such as from 60 to 130 0C, such as from 70 to 130 0C, such as from 60 to 120 0C, such as from 70 to 120 0C, such as from 60 to 1 10 0C, such as from 70 to 110 0C, such as from 60 to 100 0C, such as from 70 to 100 0C, such as from 60 to 90 0C, such as from 70 to 90 0C Preferably when step d(i) is followed, the crude product is dried by heating the crude product to a temperature of from 35 to 150 0C, such as from 35 to 140 0C1 such as from 35 to 130 0C, such as from 35 to 120 0C, such as from 35 to 110 0C, such as from 35 to 100 0C, such as from 35 to 90 0C, such as from 35 to 80 0C, such as from 35 to 70 0C1 such as from 35 to 60 0C, such as from 35 to 50 0C Preferably when step d(i) is followed, the crude product is dried by heating the crude product to a temperature of from greater than 40 to 150 0C, such as from greater than 40 to 140 0C1 such as from greater than 40 to 130 0C, such as from greater than 40 to 120 0C, such as from greater than 40 to 110 0C1 such as from greater than 40 to 100 0C, such as from greater than 40 to 90 0C, such as from greater than 40 to 80 0C, such as from greater than 40 to 70 0C, such as from greater than 40 to 60 0C, such as from greater than 40 to 50 0C. We have found that heating the crude product to a temperature of no greater than 9O0C and sufficient to provide a water evaporation rate of 0.05 to 1 5 kg water per hour per kg of dry product is particularly preferred. In this aspect, the average crystal size does not significantly increase during drying and the advantageous average crystal sizes described herein may be provided
Preferably when step d(i) is followed, the crude product is dried by exposing the crude product to a temperature of no greater than 150 0C, preferably exposing the crude product to a temperature of no greater than 140 0C, preferably exposing the crude product to a temperature of no greater than 130 0C, preferably exposing the crude product to a temperature of no greater than 120 0C1 preferably exposing the crude product to a temperature of no greater than 110 0C, preferably exposing the crude product to a temperature of no greater than 100 0C, preferably exposing the crude product to a temperature of no greater than 90 0C, preferably exposing the crude product to a temperature of from 60 to 150 0C, preferably exposing the crude product to a temperature of from 70 to 150 0C, preferably exposing the crude product to a temperature of from 60 to 140 0C, preferably exposing the crude product to a temperature of from 70 to 140 0C5 preferably exposing the crude product to a temperature of from 60 to 130 0C, preferably exposing the crude product to a temperature of from 70 to 130 0C, preferably exposing the crude product to a temperature of from 60 to 120 0C, preferably exposing the crude product to a temperature of from 70 to 120 0C, preferably exposing the crude product to a temperature of from 60 to 1 10 0C, preferably exposing the crude product to a temperature of from 70 to 1 10 0C, preferably exposing the crude product to a temperature of from 60 to 100 0C, preferably exposing the crude product to a temperature of from 70 to 100 0C, preferably exposing the crude product to a temperature of from 60 to 90 0C1 preferably from 70 to 90 0C
Preferably when step d(i) is followed, the crude product is dried to between 5-10 wt% moisture by exposing the crude product to a temperature from 35-90 0C and sufficient to provide a water evaporation rate of 0 05 to 0 5 kg water per hour per kg of dry product
Preferably when step d(ii) is followed, the crude product is dried by exposing the crude product to flash drying or spray drying at a water evaporation rate of 900 to 40000 kg water per hour per kg of dry product
Preferably when step d(ii) is followed, the crude product is dried by exposing the crude product to flash drying at a water evaporation rate from 1500 to 50000 or exposing the product to spray drying at a water evaporation rate from 500 to 1500 kg water per hour per kg of dry product. More preferably either from 20000 to 50000 by flash drying or from 900 to 1 100 by spray drying
Preferably when step d(ii) is followed, the crude product is dried by exposing the crude product to flash drying or spray drying at a water evaporation rate of 500 to 50000 kg water per hour per kg of dry product, a delta T from 0 30 to 0 80 and residence time of product in dryer of less than 5 minutes
Before step (a) of the present method, after step (d) of the present method, between any one of steps (a), (b), (c) and (d) of the present method, one or more additional steps may be provided These additional steps are encompassed by the present method For example, in one preferred aspect, the crude product is washed prior to step (d) An additional process step according to one aspect of the present invention comprises performing ion exchange on the mixed metal compound This may be performed at any time during the process, such as when present in the slurry, as a crude product or a dried product. A preferred ion exchange is in respect of sulphate present in the mixed metal compound. Ion exchange performed in respect of sulphate present in the mixed metal compound is preferably performed by exchanging sulphate with carbonate, for example by contacting the mixed metal compound with a carbonate containing solution.. Thus in this aspect, there is provided a method of producing a mixed metal compound comprising
at least Mg2+ and at least Fe3+
having an aluminium content of less than 10000 ppm,
having an average crystal size of less than 20nm (200A)
comprising the steps of:
(a) combining a Mg2+ salt and a Fe3* salt with Na2CO3 and NaOH to produce a slurry, wherein the pH of the slurry is maintained at from 9.5 to 11 , and wherein the Na2CO3 is provided at an excess of 0 to 4.0 moles (such as an excess of 2,0 to 4 0 moles) than is required to complete the reaction
(b) subjecting the slurry to mixing under conditions providing a power per unit volume of 0.03 to 1.6kW/m3
(c) separating the mixed metal compound from the slurry, to obtain a crude product having a dry solid content of at least 10 wt%
(d) drying the crude product either by
(i) heating the crude product to a temperature of no greater than 15O0C and sufficient to provide a water evaporation rate of 0 05 to 1 5 kg water per hour per kg of dry product, or
(ii) exposing the crude product to rapid drying at a water evaporation rate of 500 to 50000 kg water per hour per kg of dry product,
(e) optionally contacting the slurry, the crude product or the mixed metal compound, with a carbonate containing solution to exchange sulphate present in the mixed metal compound with carbonate
The separation of the product may be performed by any suitable method For example the mixed metal compound may be separated from the slurry by centrifugation Different filtration methods may be utilized but a preferred aspect is obtained by a filtration method using centrifugation which combines filtration followed by washing and de-watering in one step Another preferred aspect is obtained by a filtration method using a belt fitter which combines filtration followed by washing and de-watering in one step
After step (d) the product may be further treated The present invention encompasses products obtained by virtue of further treatment In one aspect the dried crude product is classified by sieving to a d50 average particle size of less than 300 μm, more preferably the dried crude product is milled to a d50 average particle size of less than 200 μm, more preferably the dried crude product is milled to a d5ϋ average particle size of less than
100 μm, more preferably the dried crude product is milled to a d50 average particle size of 2 to 50 μm, more preferably the dried crude product is mϋled to a d50 average particle size of 2 to 30 μm
Preferably, as measured by sieving, less than 10% by weight of particles are greater than 106 μm in diameter, more preferably less than 5%. Most preferably, no particles are greater than 106μm in diameter as measured by sieving
After step d(i) the product may be further treated. The present invention encompasses products obtained by virtue of further treatment In one aspect the dried crude product is mϋled More preferably the dried crude product is milled to a d50 average particle size of less than 10 μm, yet more preferably the dried crude product is milled to a d50 average particle size from 2-10 μm most preferred the dried crude product is milled to a d50 average particle size from 2-7 μm, yet most preferred the dried crude product is milled to a d50 average particle size of approximately 5 μm Preferably, after step d(i) the dried crude product is mϋled to provide a surface area of 40-80 ma/g, more preferably to a surface area of 40-70 m2/g, even more preferably to a surface area of 45-65 m2/g, most preferred to a surface area of 50-60 rri2/g
Preferably, after step d(i) the dried crude product is mϋled to a d50 average particle size from 2-10 μm and a surface area of 40-80 mz/g compound
Preferably, after step d(ii) the dried product is not milled Preferably, after step d(ii) the dried product has a d50 average particle size from 10-50 μm and a surface area of 80- 145 m2/g compound Preferably the dried crude product has a water content of less than 15 wt%, preferabiy the dried crude product has a water content of less than 10 wt%, preferably the dried crude product has a water content from 1-15 wt%, preferably the dried crude product has a water content from 5-15 wt%, preferably the dried crude product has a water content from 5-10 wt%, preferably the dried crude product has a water content from 8-15 wt%, preferably the dried crude product has a water content from 8-11 wt%, based on the total weight of the dried crude product
Preferably the mixed metal compound has a dry solid content of at least 10 wt% Preferably the mixed metal compound has a dry solid content of at least 15 wt% More preferabiy the mixed metal compound has a dry solid content of at least 20 wt%
When dried, the mixed metal compound has a dry solid content of at least 80 wt% Preferably, the dried mixed metal compound has a dry solid content of more than 85 wt%. Preferably the dried mixed metal compound has a dry solid content of less than 99 wt%. More preferably the dried mixed metal compound has a dry solid content of less than 95 wt%. Most preferred the dried mixed metal compound has a dry solid content from 90 to 95 wt% As discussed herein, the compound has a average crystal size of less than 20nm (200A) Preferabiy the compound has a average crystal size of from 100 to 200 A Preferably the compound has a average crystal size of from 155 to 200 A Preferably the compound has a average crystal size of from 1 10 to 195 A Preferably the compound has a average crystal size of from 1 10 to 185 A, Preferably the compound has a average crystal size of from 1 15 to 165 A. Preferably the compound has a average crystal size of from 120 to 185 A, Preferably the compound has a average crystal size of from 130 to 185 A Preferably the compound has a average crystal size of from 140 to 185 A Preferably the compound has a average crystal size of from 150 to 185 A Preferably the compound has a average crystal size of from 150 to 175 A More preferably the compound has a average crystal size of from 155 to 175 A. More preferably the compound has a average crystal size of from 155 to 165 A
In a further preferred embodiment there is provided for the production of a mixed metal compound having an average crystal size of less than 13nm (130A) and a phosphate binding capacity of more than 0.65 mmo! phosphate/g mixed metal compound !n a further preferred embodiment there is provided for the production of a mixed metal compound having an average crystal size of less than 9nm (90A) and a phosphate binding capacity of more than 0 70 mmol phosphate/g mixed metal compound In one preferred aspect the present invention provides a mixed rneta! comprising at least Mg2+ and at least Fe3+ wherein the molar ratio of Mg2+ to Fe3+ is 2.1 "! to 1 7:1 having an aluminium content of less than 30 ppm, having a average crystal size from 110-195 A, having an interiayer sulphate from 2 1 to 5 wt% (such as from 2 1 to 3 2 wt%) comprising the steps of
(a) combining a Mg2+ sait and a Fe3+ salt with Na2CO3 and NaOH to produce a slurry, wherein the pH of the slurry is maintained at from 9 6 to less than 10, and wherein the Na2CO3 is provided at an excess of 21 moles than is required to complete the reaction
(b) subjecting the slurry to mixing under conditions providing a power per unit volume of 0 05 to 0 05 kW/m3
(b1 ) controlling the slurry to a temperature from 20 to 25 0C
(b2) optionally controlling the slurry to a dSO psd of at least 40 μm (preferably controlling the slurry to a d50 psd of at least 40 μm)
(c) separating the mixed metal compound from the slurry, to obtain a crude product having a dry solid content of at least 10 wt%
(d) (i) drying the crude product to 5-10 wt% moisture by exposing the crude product to a temperature from 40-90 0C and sufficient to provide a water evaporation rate of 0 05 to 0 5 kg water per hour per kg of dry product
The compound prepared by the present method may be any mixed metal compound comprising Mg2+ and at least Fe3+ In one preferred aspect, the compound is a compound having a hydrotalcite structure Preferably the compound is of the formula
Mil 1-χM!")((OH)aAn' y mH2O (II)
wherein Ml! is one or more bivalent metals and is at least Mg2*;
M!!l is one or more trivalent metals and is at least Fe3+;
Aπ" is one or more n-va!ent anions and is at least CO3 2";
1 0 < x / Σyn < 1.2, 0 < x < 0 67, 0 < y≤ 1 and 0 < m≤10
The method by which the molecular formula of a mixed metal compound may be determined will be well known to one skilled in the art. It will be understood that the molecular formula may determined from the analysis of M" / M1" ratio (Test Method 1 ), SO4 analysis (Test Method 5), CO3 analysis (Test Method 6) and H2O analysis (Test Method 12)
Preferably, O < x < 0,4, O < y≤ 1 and O < m < 10.
Preferably 1.05 < x /∑yn < 1.2, preferably 1 05 < x /∑yπ < 1 15 In one preferred aspect x /∑yn = 1
In one preferred aspect 0.1 < x, such as O 2 < x, O 3 < x, 0.4 < x, or 0.5 < x. In one preferred aspect O < x < 0,5. It will be understood that x = [Mllf]/([M!I] + [M111]) where [M11] is the number of moles of M!l per mole of compound of formula I and [M1"] is the number of moles of M!" per mole of compound of formula I.
In one preferred aspect 0 < y≤ 1 Preferably 0 < y≤ 0 B Preferably 0 < y≤ 0 6, Preferably 0 < y < 0 4 Preferably 0 05 < y < 0 3 Preferably 0.05 < y < 0 2. Preferably 0.1 < y≤ 0 2, Preferably 0,15 < y≤ 0 2
In one preferred aspect 0≤ m≤ 10. Preferably 0≤ m≤ 8. Preferably 0≤ m≤ 6 Preferably 0≤ m≤ 4 Preferably 0≤ m≤ 2 Preferably 0≤ m≤ 1. Preferably 0≤ m≤ 0 7, Preferably 0≤ m≤ 0.6, Preferably 0 1≤ m≤ 0 6 Preferably 0 < m≤ 0 5 Preferably 0 < m ≤ 0,3. Preferably 0 < m≤ 0.15 Preferably 0.15≤ m≤ 0.5 The number of water molecules m can include the amount of water that may be absorbed on the surface of the crystallites as well as interlayer water The number of water molecules is estimated to be related to x according to: m = 0,81 - x.
It will be appreciated that each of the preferred values of x, y, z and m may be combined
In one preferred aspect the compound has an aluminium content of less than 5000 ppm, more preferably less than 1000 ppm, most preferred 100 ppm, most preferably 30 ppm
In one preferred aspect the total sulphate content of the compound is from 1 .8 to 5 wt% By total sulphate content it is meant content of sulphate that is present in the compound, This may be determined by well known methods and in particular determined in accordance with Test Method 1 , Preferably the total sulphate is from 2 to 5 wt% preferably from 2 to 3,7 wt%, preferably from 2 to 5 wt%, preferably from 2 to less than 5 wt%, preferably from 2.1 to 5 wt% preferably from 2,1 to less than 5 wt%, preferably from 2 2 to 5 wt%, preferably from 2 2 to less than 5 wt%, preferably from 2 3-5 wt%, preferably from 2 3 to less than 5 wt%
In one preferred aspect the total sulphate content of the compound is from 1 8 to 4 2 wt% By total sulphate content it is meant content of sulphate that is present in the compound This may be determined by well known methods and in particular determined in accordance with Test Method 1 Preferably the total sulphate is from 2 to 4 2 wt% preferably from 2 to 3 7 wt%, preferably from 2 to 3 2 wt%, preferably from 2 to less than
3 2 wt%, preferably from 2 1 to 3 2 wt% preferably from 2 1 to less than 3 2 wt%, preferably from 2 2 to 3 2 wt%, preferably from 2 2 to less than 3 2 wt%, preferably from
2 3-3 2 wt%, preferably from 2 3 to less than 3 2 wt%
The compound will also contain an amount of sulphate that is bound within the compound This content of sulphate, the interlayer sulphate, may not be removed by a washing process with water As used herein, amounts of interlayer sulphate are the amount of sulphate as determined in accordance with Test Method 5 In a preferred aspect the interlayer sulphate content of the compound is from 1 8 to 5 wt%, preferably from 1 8 to 3 2 wt%, preferably from 2 to 5 wt%, preferably from 2 to less than 5 wt%, preferably from 2 to 3 2 wt%, preferably from 2 to 3 1 wt%, preferably from 2 to 3 0 wt% Preferably the interlayer sulphate content of the compound is from 2 1 to 5 wt%, preferably from 2 1 to 3 2 wt%, preferably from 2 1 to less than 3 2 wt% More preferably the interlayer sulphate content of the compound is from 2 2 to 5 wt%, preferably from 2 2 to 3 2 wt%, preferably from 2,2 to less than 3 2 wt% Yet more preferably the interlayer sulphate content of the compound is from 2 3 to 5 wt%, preferably from 2,3 to 3 2 wt%, preferably from 2 3 to less than 3 2 wt% Most preferably the interlayer sulphate content of the compound is from 2 5 to 5 wt%, preferably from 2 5 to 3 2 wt%, preferably from 2 5 to less than 3.2 wt% Yet most preferred the interlayer sulphate content of the compound is from 2 5 to 3 0 wt% As discussed herein, the present invention provides novel compounds As discussed herein, the present invention provides a mixed metal compound comprising at least Mg2+ and at least Fe3+,
wherein
the molar ratio of Mg2+ to Fe3+ is 2 5.1 to 1 5-1 ,
the mixed metal compound has an aluminium content of less than 10000 ppm, the average crystal size of the mixed metal compound is from 10 to 20nm (100 to 200A), and the d50 average particle size of the mixed metal compound is less than 300 μm Preferably the d50 average particle size of the mixed metal compound is less than 200 μm As discussed herein, the present invention provides a mixed metal compound comprising at least Mg2+ and at least Fe3+,
wherein
the moiar ratio of Ug2* to Fe3+ is 2 5.1 to 1 ,5.1 ,
the mixed meta! compound has an aluminium content of less than 10000 ppm, the average crystal size of the mixed metal compound is from 10 to 20nm (100 to 200A), and the water pore volume of the mixed metal compound is from 0,25 to 0 7 cm3/g of mixed meta! compound Preferably the water pore volume of the mixed metal compound is from 0 3 to 0 65 cm3/g of mixed metal compound Preferably the water pore volume of the mixed metal compound is from 0 35 to 0 65 cm3/g of mixed metal compound Preferably the water pore volume of the mixed meta! compound is from 0 3 to 0 6 cm3/g of mixed metal compound in further preferred embodiment of this aspect the nitrogen pore volume of the mixed metai compound is from 0 28 to 0.56 cm3/g As used herein, the term 'nitrogen pore volume' refers to the pore volume as determined in accordance with Test Method 14 When the nitrogen pore volume of the mixed metal compound is from 0 28 to 0 56 cm3/g it has been found that the close correlation to the water pore volume is such that the water pore volume need not be determined Thus in a further aspect the present invention provides a mixed metal compound comprising at least Mg2+ and at least Fe3+, wherein
the molar ratio of Mg2+ to Fe3+ is 2 5:1 to 1 5:1 ,
the mixed metal compound has an aluminium content of less than 10000 ppm, the average crystal size of the mixed metal compound is from 10 to 20nm (100 to 200A), and the nitrogen pore volume of the mixed metal compound is from 0 28 to 0 56 cm3/g.
As discussed herein, the present invention provides a mixed metal compound comprising at least Mg2+ and at least Fe3+,
wherein
the molar ratio of IvIg2+ to Fe3+ is 2 5.1 to 1 5: 1,
the mixed metal compound has an aluminium content of less than 10000 ppm, the average crystal size of the mixed metal compound is from 10 to 20nm (100 to 200A)1 and the inieriayer sulphate content of the compound is from 1 8 to 5 wt% (such as from 1 8 to 3 2 wt%) Preferably the average crystal size of the mixed metal compound is from 12 to 20nm (120 to 200A) As discussed herein, the present invention provides a mixed metai compound comprising at least Mg2+ and at least Fe3+,
wherein
the molar ratio Of Mg2+ to Fe3+ is 2,5:1 to 1 5:1,
the mixed metai compound has an aluminium content of less than 10000 ppm, the average crystal size of the mixed metal compound is less than 20nm (200A), and the interlayer sulphate content of the compound is from 2 1 to 5 wt% (such as from 1.8 to 3 2 wt%) Preferably the average crystal size of the mixed metal compound is from 10 to 20nm (100 to 200A) As discussed herein, the present invention provides a mixed metal compound comprising at least Mg2+ and at least Fe3+,
wherein
the molar ratio Of Mg2+ to Fe3+ is 2 5:1 to 1.5:1 ,
the mixed metal compound has an aluminium content of less than 10000 ppm, the average crystal size of the mixed metal compound is less than 20nm (200A)1 and the surface area is from 80 to 145m2 per gram of compound Preferably the compound has a d50 average particle size of from 10 to 350 μm (and preferably wherein the compound has not been subject to milling) Preferably the compound has a d50 average particle size of from 10 to 300 μm Preferably the compound has a d50 average particle size of from 10 to 210 μm Preferably the compound has a d50 average particle size of from 10 to 100 μm. Preferably the compound has a d50 average particle size of from 10 to 50 μm Preferably the compound has a d50 average particle size of from 10 to 35 μm Preferably the compound releases magnesium in an amount is less than 0 15 mmol magnesiurn/g compound The magnesium release is determined in accordance with Test Method 3
As discussed herein, the present invention provides a mixed metal compound comprising at least Mg2+ and at least Fe3+,
wherein
the molar ratio of Mg2+ to Fe3+ is 2.5: 1 to 1 5: 1 ,
the mixed metal compound has an aluminium content of less than 10000 ppm, the average crystal size of the mixed metal compound is from 10 to 20nm (100 to 200A), the surface area is from 40 to 80 m2 per gram of compound
Preferably the d50 average particle size of the mixed metal compound is less than 100 μm Preferably the d50 average particle size of the mixed metal compound is less than 50 μm Preferably the d50 average particle size of the mixed metal compound is less than 20 μm Preferably the d50 average particle size of the mixed metal compound is less than 10 μm. Preferably the d50 average particle size of the mixed metal compound is approximately 5 μm. Preferably the water pore volume of the mixed metal compound is from 0.25 to 0.7 crrvVg of mixed metal compound, preferably the water pore volume is from 0.3 to 0,65 cm3/g of mixed metal compound, preferably the water pore volume is from 0.3 to 0 6 cm3/g of mixed metal compound Preferably the nitrogen pore volume of the mixed metal compound is from 0 28 to 0 56 cm3/g of mixed metal compound
In each of the aspects of the invention in which a mixed metal compound is provided, preferably
(1 ) the interlayer sulphate content of the compound is from 2.2 to 5 wt% (such as from 1.8 to 3.2 wt%), and/or
(2) the compound is of the formula
M1VxM111 X(OH)2A0V mH2O
wherein M" is one or more bivalent metals and is at least Mg2+;
M111 is one or more trivaient metals and is at least Fe3+,
An" is one or more n-valent anions and is at least CO3 2",
x/∑yn is from 1 to 1.2 (preferably x/∑yn is from 1 05 to 1 15, preferably x/∑yn is 1)
0 < x≤ 0.4,
0 < y≤ 1 and
0 < m≤ 10, and/or
(3) the compound has an aluminium content of less than 100 ppm, preferably an aluminium content of less than 30 ppm
(4) the interlayer sulphate content of the compound is from 1 8 to 5 wt% (such as from 1.8 to 3.2 wt%), and/or
(5) the compound has a d50 average particle size of less than 100 μm. preferably the compound has a d50 average particle size of 5 to 50μm, preferably the compound has a d50 average particle size of approximately 5 μm and/or
(6) the water pore volume of the mixed metal compound is from 0.3 to 0.65 cm3/g of mixed metal compound and/or
(7) the compound has a dry solid content of at least 20 wt% The compound may have any degree of porosity, subject to any range specified herein In a preferred aspect the water pore voiume of the mixed metal compound is from ϋ 25 to ϋ 7 cm3/g of mixed metal compound In a preferred aspect the water pore volume of the mixed metal compound is from 0 3 to 0 65 cm3/g of mixed metal compound
Preferably the mixed metal compound comprises at least some material which is a Layered Double Hydroxide (LDH) More preferably, the mixed metal compound of formula (I) is a layered double hydroxide As used herein, the term "Layered Double Hydroxide" is used to designate synthetic or natural lamellar hydroxides with two different kinds of metallic cations in the main layers and interiayer domains containing anionic species This wide family of compounds is sometimes also referred to as anionic clays, by comparison with the more usual cationic clays whose interlameliar domains contain cationic species LDHs have also been reported as hydrotalcite-like compounds by reference to one of the polytypes of the corresponding [Mg-AIj based mineral
A particularly preferred mixed metal compound contains at least one of carbonate tons, and hydroxyl ions A particularly preferred compound contains as M" and Mιsι, magnesium and iron (III) respectively
PROCESS The mixed metal compound or compounds may be suitably made by co-precipitation from a solution, followed by centrifugation or filtration, then drying, milling and/or sieving The mixed metal compound may then be rewetted as part of the wet-granulation process and the resulting granules dried in a fluid-bed dryer The degree of drying in the fluid-bed is used to establish the desired water content of the final tablet
Two methods of coprecipitation may be used, namely one at low supersaturation whereby the pH of the reaction solution is maintained constant by controlling the addition of a second solution of an alkali, or alternatively precipitation at high supersaturation whereby the pH of the reaction solution is continuously changed by addition of the mixed metal solution to an alkali solution already present in the reactor vessel The precipitation method whereby the pH is kept constant is preferred as this avoids the formation of single metal compounds such as M(OH)2 and/or M(OH)3 phases instead of mixed meta! compound
Other precipitation methods of the mixed metal compound may also be possible if the crystallite size is controlled to less than 200 A. For example, a precipitation method involving separate nucleation and aging steps, an urea hydrolysis method, an induced hydrolysis method, a sait-oxide method, a sol-gel method, an electrosynthesis method, an in situ oxidation of the divalent meta! ion to a trivalent metal ion, a so-called "Chimie
Douce" method or a method wherein the mixed metal compound may be formed by heating an intimate mixture of finely divided single metal saits at a temperature whereby solid-soiid reaction can occur, leading to a mixed metal compound formation.
Post synthesis methods that tend to promote ageing are less preferred but may be used if crystallite size is controlled to less than 200 A Examples of possible post synthesis heat-treatment steps include hydrothermal, microwave and ultrasound.
A variety of methods can be used to separate the mixed metal compound from the reaction slurry. Different washing, drying and milling methods are also possible where crystallite size is less than 200 A
The substances of the invention prepared by treatment of a suitable starting material as hereinbefore described may be prepared by providing a first solution of a water soluble compound of metal M" and a water soluble compound of metal M1", the anions being chosen so as not to result in precipitation from the first solution (A). A second solution (B) is also provided, of a water soluble hydroxide (e g NaOH) and a water soluble salt of anion Aπ" (the cation being chosen so as not to precipitate with the hydroxide or the anion with the metal from the hydroxide) The two solutions are then combined and the mixed metal compound starting material is formed by co-precipitation. For example, Solution A is made up by dissolving magnesium sulphate and ferric sulphate in purified water Solution B is made up by dissolving sodium carbonate and sodium hydroxide in purified water A heel of purified water is added to a reactor, the solutions A and B are fed in a ratio controlled manner. After the product forms in the reactor it may comprise solid crystalline material, usually also with the presence of some solid amorphous material. Preferably, at least some of the material so formed is of a layered double hydroxide and/or of a hydrotalcite structure, usually also with some amorphous and/or poorly crystalline material, preferably after co-precipitation, the material is then filtered or centrifuged, washed then dried by heating The drying is carried out either by (i) exposing the crude product to a temperature of no greater than 15O0C and sufficient to provide a water evaporation rate of 0 05 to 1 5 kg water per hour per kg of dry product, or (ii) exposing the crude product to flash drying or spray drying at a water evaporation rate of 500 to 50000 kg water per hour per kg of dry product, for example by oven drying, spray drying or fluid bed drying
Optionally, the dry material may be first classified, to remove oversize particles by milling and/or sieving and/or any other suitable technique, for example to restrict the material to be treated to particles which are substantially no greater than 300μm in diameter
Reaction
A wide number of options are available for carrying out the reaction These may be controlled in order to carry out the reaction in the manner desired For example, the reactant equipment type, reactant stream composition, temperature and pH, mode of reactant addition, agitation system, and hold time may all be specified in order to produce a desired reaction Various reactor types are common in the pharmaceutical industry, these include Batch and Continuous reactors
The materia! structure and crystallite size can be significantly determined at the reaction stage by close control of the reactant solution concentration, the reaction temperature, the time that the reaction mass is held following precipitation and the mode of reactant addition Furthermore, in order to achieve the preferred material structure with small crystallite size, a high solution concentration (at end of reaction period of 4 8 - 5.4 wt%), low reaction temperature (15 - 25°C) and short hold time (typically < 12 hours) are preferred
To prepare the mixed metal compounds to a preferred Mg: Fe molar ratio, for example from 1 5:1 to 2 5:1 then precise control of pH during the precipitation process is desirable. Precise pH control is typically achieved by frequent calibration of pH electrodes and monitoring and adjustment of the pH throughout the precipitation process. The pH of the reaction may be controlled by varying the relative rate of addition of Solution A to Solution B added to the reactor. We have found that the variation of Solution B only is preferred since this maintains the precipitate concentration in the reaction mix at a constant level, The variation in Solution B flow rate can be carried out manuaiiy or using a suitable control algorithm We have found an optimal reactant composition, whereby opposing requirements of maintaining a relatively low reaction temperature, but achieving reasonable filtration rate and good pH control, are met.
For example, the preferred M2+ : M3+ molar ratio between 1 5.1 to 2 5:1 of the mixed metal compound can be achieved by maintaining the reactant streams in solution even at relatively low temperatures, thereby limiting the reaction temperature The reaction temperature can be important in determining the extent of crystallite growth and hence the phosphate binding activity The preferred method allows good filtration rates to be achieved, this again can be important in limiting the reaction mass storage time which in term is known to help determine the extent of crystallite growth, and hence the phosphate binding activity
Further, the preferred reaction conditions and recipe helps to maintain good pH control Good pH control is required in order to achieve the target pH
The mode of reactant stream addition can be important in defining the reaction product quality Different combinations of addition mode are possible and may include the addition of one reactant stream into an excess of the other reactant (either reactant could be selected as the added stream)
We have found that simultaneous addition of a high pH reactant stream containing carbonate and hydroxide ions, and a low pH reactant stream containing metal and sulphate ions into a heel provides more accurate pH control of the reaction slurry Therefore, in a preferred embodiment, the reaction is carried out by simultaneous addition (co-precipitation) of a reactant stream containing carbonate and hydroxide ions, and a reactant stream containing metal and sulphate ions
Similarly, the product can be removed on a continuous basis as the reactant streams are added, or at the end of a defined period Good filtration characteristics are achieved by targeting a reiativeiy large particle size such as of at least 40 μm by controlling the power per unit voiume from 0 03 to 1 6 kW/m3 We have identified that power per unit volume of 0 05 to 0 5 kW/m3 using impeller(s) configured for axial flow agitation, helps to produce a slurry with further improved filtration characteristics (such as lower filtration and washing time, and high final solids content in cake)
Therefore, in a preferred embodiment, agitation is used to subject the slurry to mixing under conditions providing a power per unit volume of 0 03 to 1 6 kW/m3 provided by static mixers, impeller agitators, pump, jet mixer or dynamic in line mixer Therefore, in a further preferred embodiment, axial flow agitation is used to subject the slurry to mixing under conditions providing a power per unit volume of 0 03 to 1.6 kW/m3 provided by an impeller agitator More preferably a power per unit volume of 0.05 to 0.5 kW/m3 delivered by impeller agitation This provides reaction slurry with the preferred filtration characteristics,
Therefore, in a separate embodiment, the reaction is agitated using means other than a conventional impeller agitator An optimum hold time has been identified as from 30 minutes to 12 hours For hold times of more than 16 hours, filtration becomes difficult due to a reduction in particle size during use of agitation in hold time and ageing occurs.
Filtration
A wide number of options are available for carrying out the product isolation and washing steps, however the filtration equipment type and operating process parameters should be carefully defined and controlled For example, in order to limit the overall reaction slurry hold time (and hence crystallite growth), it is beneficial to minimise the time for cake isolation and wash time A high cake solids content is also preferable as this reduces the drying time and hence the propensity for crystallite growth during the drying step Various filter types are used in the pharmaceutical industry, these include: Neutsche filters, Filter dryers, Filtering centrifuges, Belt filters, Plate and frame filters. When isolating the unaged mixed metal compound, the overall filtration rate can be extremely low due to the relative difficulty of isolating and washing these unaged clay- type mixed meta! compounds making this economically unattractive if not controlled to the preferred conditions, The unaged material of crystallite size of less than 200 A, has the tendency to result in 'blinding' of the filtration media and/or the clay-type properties have a tendency to form a more impermeable cake.
In one preferred embodiment we have produced high filtration rate using a belt filter
A wide number of options are available for carrying out the drying operation, these should be defined and controlled in order to carry out the drying step in the best manner
For example, the dryer type, mode of drying, and rate of drying should be specified and controlled such that the crude product is dried either by (i) exposing the crude product to a temperature of no greater than 150 0C and sufficient to provide a water evaporation rate of 0 05 to 1 ,5 kg water per hour per kg of dry product, or (ii) exposing the crude product to flash drying or spray drying at a water evaporation rate of 500 to 50000 kg water per hour per kg of dry product. The rate of drying is affected by factors including the mode of drying, heated surface/ heating medium temperature, degree of agitation, vacuum level (if any) etc The product temperature must be limited to no greater than 150 0C to prevent damage to the drug substance.
Various dryer types are common in the pharmaceutical industry, these include long residence time dryers (characterised as typically up to 20 h residence time) such as Spherical, Conical, Double cone, Tray dryer (vacuum, ambient pressure), and short residence time dryers (characterised as typically up to several minutes residence time) include; Spray, Spin flash, Etc.
We have found that of the various batch dryer designs an agitated spherical dryer offers a large heated surface area to the product. Therefore a higher product rate per unit area from 1 to 2.1 kg product / (m2 hr) and thus high heat transfer and drying rates are possible. Since ageing (crystallite growth) can occur during drying, it is important to minimise the drying time / maximise drying rate In order to prevent decomposition of the drug substance, where surface heating is used the drying surface temperature is typically limited to 15O0C for batch drying and preferably 90 0C or less to avoid average crystal size growth to above 200 A Partial evacuation of the dryer depresses the boiling point of water in the drying mass, thereby limiting crystal growth, this depression also serves to maximise the drying rate The drying rate is manipulated by maximising the dryer vacuum and /or increasing the shell temperature up to 120 0C during an initial drying phase, to remove water at the highest possible rate, and then reducing the rate by reducing the shell temperature to less than 90 0C, in order to accurately target a defined moisture end point whilst maintaining a crystallite size less than 200 A The moisture end point can be inferred by monitoring the evaporation mass, or measured directly, by analysis of the dried contents, or other suitabie methods
Conical dryers (e g Nautamixer type) offer similar benefits to the spherical dryer Vacuum tray dryers were found to produce an acceptable product quality, however this type of dryer can require manual intervention (e g redistribution of soϋds) for uniform drying, and has limited throughput.
The long residence time batch dryers described (spherical, conical, vacuum) all have relatively low drying rates (expressed in normalised terms as kg evaporation per kg product per hour) when compared to the short residence time drying methods We have found that the temperature of the drug substance during drying and the drying rate can significantiy influence the crystallite size and morphology of the drug substance For example, long residence time batch drying tends to produce a relatively large average crystal size and relatively low pore volume and surface area, whereas short residence methods such as spray drying and spin flash drying have been found to produce relatively smailer crystals with relatively large pore voiume and surface area Material produced using short residence time drying can show an enhanced phosphate binding performance; this may be due to the different crystallite and morphological properties Spray dried material has the additional advantage of granulation for just dry blending (e g. for tablet manufacture) and may be carried out without prior milling of the drug substance. Long residence drying time methods are typically defined as having a residence time equal to or greater than 3 hours Examples of these include: tray drying, kettle drying, pan drying, rotary (shell) drying, rotary (internal) drying, double cone drying We have found average evaporation rates of between 9 and 29 kg water/(h m2) are achievable using an agitated vacuum spherical dryer Stated on an alternative basis this is equivalent to an evaporation rate of approximately 0 05 to 0 5 kg water per hour per kg of dry product The product crystallite size produced at this range of evaporation rates is typically between 100 - 200 Angstroms For a dried product of consistent quality the dryer must be fed with a wet cake (typically > 20 wt% solids)
Each of the above dryers is operated on a batch basts
Short residence drying time method examples typically have much lower residence times These differ depending upon technology types and are defined as: spin flash drying, typical residence time of 5 to 500 seconds / spray drying, typical residence time up to 60 seconds
Typical evaporation rates are defined as. spin flash 70 - 300 kg water/(h m3) vessel volume, spray 5 - 25 kg water/(h m3) vessel volume Evaporation rates for spin flash and spray dryers are also calculated as 500 to 50000 kg water/(h kg drug) The product crystallite size produced at this range of evaporation rates is typically less than 140
Angstroms The spin flash dryer may be fed with wet cake (typically > 20 wt% solids), whereas the spray dryer must be fed with a free flowing slurry at a Sower concentration (typically to 10 wt% solids)
The above short residence time dryers may all be operated on a continuous basis
Various 'medium' residence time technologies can be used which predominantly rely on the use conveyors and are operated continuously These may be less preferred if problems occur in terms of ensuring a consistent quality of product (variable moisture content) and cleanliness for pharmaceutical production. Examples of medium residence time technologies are listed as: Rotary shelf, Trough Vibrating, Turbo type USES
Preferably the compound is used in the manufacture of a medicament for the prophylaxis or treatment of hyperphosphataemia
In a further aspect the present invention provides use of a compound of the present invention or obtained/obtainable in accordance with the present invention in the manufacture of a medicament for the prophylaxis or treatment of any one of hyperphosphataemia, renal insufficiency, hypoparathyroidism, pseudohypoparathyroidism, acute untreated acromegaly, chronic kidney disease and over medication of phosphate salts
Examples of one or more of the symptoms which may indicate risk for the presence of CKD' a creatine concentration of above 1 6 mg/dL, a blood phosphate level of above 4 5 mg/dL( any detectable blood in urine, urine protein concentration above 100 mg/dL, a urine aibumin concentration above about 100 mg/dL, a glomerular filtration rate (GFR) of below 90 mL/min/1 73 m2 or a parathyroid hormone concentration in the blood above 150 pg/mL The symptoms are also defined by the National Kidney Foundation-Fidney Disease Outcomes Quality Initiative "NKF-K/DOQi" or "K/DOQI/ in one preferred aspect the chronic kidney disease (CKD) treated in accordance with the presence invention is CKD having stage one to five
The medicament may be used on animals, preferably humans
PHARMACEUTICAL COMPOSITIONS
A pharmaceutically acceptable carrier may be any material with which the substance of the invention is formulated to facilitate its administration. A carrier may be a solid or a liquid, including a material which is normally gaseous but which has been compressed to form a liquid, and any of the carriers normally used in formulating pharmaceutical compositions may be used Preferably, compositions according to the invention contain 0.5% to 95% by weight of active ingredient. The term pharmaceutically acceptable carrier encompasses diluents, excipients or adjuvants. When the substances of the invention are part of a pharmaceutical composition, they can be formulated in any suitable pharmaceutical composition form e g. powders, granules, granulates, sachets, capsules, stick packs, battles, tablets but especially in a form suitable for oral administration for example in solid unit dose form such as tablets, capsules, or in liquid form such as liquid suspensions, especially aqueous suspensions or semi-solid formulations, e,g gels, chewy bar, dispersing dosage, chewable dosage form or edible sachet Direct addition to food may also be possible
Dosage forms adapted for extra-corporeal or even intravenous administration are also possible. Suitable formulations can be produced by known methods using conventional solid carriers such as, for example, lactose, starch or talcum or liquid carriers such as, for example, water, fatty oils or liquid paraffins Other carriers which may be used include materials derived from animal or vegetable proteins, such as the gelatins, dextrins and soy, wheat and psyllium seed proteins; gums such as acacia, guar, agar, and xanthan, polysaccharides, alginates, carboxymethylcelluloses, carrageenans; dextrans; pectins; synthetic polymers such as polyvinylpyrrolidone, polypeptide/protein or polysaccharide complexes such as gelatin-acacia complexes, sugars such as mannitol, dextrose, galactose and trehalose, cyclic sugars such as cyclodextrin; inorganic salts such as sodium phosphate, sodium chloride and aluminium silicates; and amino acids having from 2 to 12 carbon atoms such as a glycine, L-alanine, L-aspartic acid, [.-glutamic acid,
L-hydroxyproiine, L-isoleucine, L-leucine and L-phenylalanine
Auxiliary components such as tablet disintegrants, solubiiisers, preservatives, antioxidants, surfactants, viscosity enhancers, colouring agents, flavouring agents, pH modifiers, sweeteners or taste-masking agents may also be incorporated into the composition, Suitable colouring agents include red, black and yellow iron oxides and FD & C dyes such as FD & C blue No. 2 and FD & C red No 40 available from Ellis & Everard Suitable flavouring agents include mint, raspberry, liquorice, orange, lemon, grapefruit, caramel, vanilla, cherry and grape flavours and combinations of these. Suitable pH modifiers include sodium hydrogencarbonate, citric acid, tartaric acid, hydrochloric acid and maleic acid. Suitable sweeteners include aspartame, acesulfame K and thaumatin. Suitable taste-masking agents include sodium hydrogencarbonate, ion- exchange resins, cyclodextrin inclusion compounds, adsorbates or microencapsulated actives, For treatment of and prophylaxis of hyperphosphataemia, preferably amounts of from 0 1 to 500, more preferably from 1 to 200, mg/kg body weight of substance of the invention as active compound are administered daily to obtain the desired results Nevertheless, it may be necessary from time to time to depart from the amounts mentioned above, depending on the body weight of the patient, the method of application, the animal species of the patient and its individual reaction to the drug or the kind of formulation or the time or interval in which the drug is applied In special cases, it may be sufficient to use less than the minimum amount given above, whilst in other cases the maximum dose may have to be exceeded. For a larger dose, it may be advisable to divide the dose into several smaller single doses Ultimately, the dose will depend upon the discretion of the attendant physician Administration soon before meals, e g within one hour before a meal or taken with food wiil usually be preferred
A typical single solid unit dose for human adult administration may comprise from 1mg to 1g, preferably from 10 mg to 800 mg of substance of the invention
A solid unit dose form may also comprise a release rate controlling additive For example, the substance of the invention may be held within a hydrophobic polymer matrix so that it is gradually leached out of the matrix upon contact with body fluids Alternatively, the substance of the invention may be held within a hydrophilic matrix which gradually or rapidly dissolves in the presence of body fluid. The tablet may comprise two or more layers having different release properties The layers may be hydrophilic, hydrophobic or a mixture of hydrophilic and hydrophobic layers Adjacent layers in a multilayer tablet may be separated by an insoluble barrier layer or hydrophilic separation layer An insoluble barrier layer may be formed of materials used to form the insoluble casing A hydrophilic separation layer may be formed from a material more soluble than the other layers of the tablet core so that as the separation layer dissolves the release layers of the tablet core are exposed. Suitable release rate controlling polymers include polyrnethacrylates, ethylcellulose, hydroxypropylmethylcellulose, methylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, sodium carboxymethylcellulose, calcium carboxymethylcellulose, acrylic acid polymer, polyethylene glycol, polyethylene oxide, carrageenan, cellulose acetate, zein etc Suitable materials which swell on contact with aqueous liquids include polymeric materials include from cross-linked sodium carboxymethylcellulose, cross-iinked hydroxypropylcellulose, high molecular weight hydroxypropylcelluiose, carboxymethylamide, potassium rnethacrylatedivinyibenzene copolymer, polymethylmethacrylate, cross-linked polyvinylpyrrolidone and high molecular weight polyvinylalcohols..
Solid unit dose forms comprising a substance of the invention may be packaged together in a container or presented in foil strips, blister packs or the like, e g marked with days of the week against respective doses, for patient guidance,
There is also a need for formulations which could improve patient compliance, for example in case of elderly or paediatric patients. A formulation in powder dose form could be either diluted in water, reconstituted or dispersed.
COMBINATIONS
The compound of the present invention may be used as the sole active ingredient or in combination with another phosphate binding agent It may also be used in combination with a calcimimetic such as cinacalet, vitamin D or calcitrio!..
In a further aspect the present invention provides use of a compound of the present invention or obtained/obtainable in accordance with the present invention in the manufacture of a medicament for the prophylaxis or treatment of hyperphosphataemia.
EXAMPLES
General description of reaction. The mixed metal compound is formed by the reaction of an aqueous mixture of magnesium sulphate and ferric sulphate with an aqueous mixture of sodium hydroxide and sodium carbonate The precipitation is carried out at a pH of around 9.8 and a reaction temperature starting at around 22 °C and rising to up to 30 °C upon addition of reactants. The resulting precipitate is filtered, washed, dried and milled
The synthesis reaction is represented thus. 4MgSO4 + Fe2(SO4)3 + 12NaOH + (XS+1 JNa2CO3 → Mg4Fe2(OH)12-CO3^H2O + 7Na2SO4 + XSNa2CO3 This generates a mixed metal compound with a molar ratio of Mg:Fe of typically 2:1 and the reaction by-product sodium sulphate. Excess (XS) sodium carbonate added to the reaction mixture along with the sodium sulphate is washed out of the precipitate
By changing the molar ratio of M11 : Mm cations to 1 1 , 2:1, 3:1, 4:1 different composition materials were achieved The excess sodium carbonate and reaction pH were also changed in separate experiments
The molecular formula of layered double hydroxides can be measured by different methods The actual method used to determine the molecular formula of the examples herein was determined from the analysis of M!l / Mll! ratio (Method 1), SO4 analysis (Method 5), CO3 analysis (Method 6) and H2O analysis (Method 12). Formula [M V xM!!l x(OH)2][(Cθ3)y1(Sθ4)y2,mH2O][Na2Sθ4]2 was used to describe the composition of the examples (1-66) shown herein below in further detail for mixed metal compound wherein" x = [Mill]/([Mn] + [M1"]) where [M11] is the number of moles of bivalent metal M11 per mole of compound of formula I and [M1"] is the number of moles of trivalent metal Mm per mole of compound of formula I
∑y' = sum of the moles interiayer anions y1 ' (CO3 2") + y2' (SO4 2') or any other anions wherein y1 ' = wt% CO3 2" / Mw CO3 2- y2' = (wt% SO/total/Mw SO4 2") - (wt% Na2O/Mw Na2O)
Interiayer anions are also defined as bound anions or anions that cannot be removed by washing with water.
∑y =∑y' * f
∑y - is the sum of moles interiayer anion corrected with the formula normalisation factor
(f) y1 = y1' * f y2 = y2' * f f = x / (2 * wt% M!II 2O3/ Mw IW2O3) = formula πormaiisation factor m' = wt% H2O / (Mw H2O)
m = m' * f
wt% H2O = LOD (loss on drying measured at 105 0C) z = z' * f z = amount of sulphate remaining thai can be removed by washing and is calculated from the amount of Na2O the total of which is assumed to be associated with SO4 2" as soluble Na2SO4 z' = wt% Na2O/Mw Na2O The ratio x /∑yπ can be calculated from the values of x and the sum of interlayer anions (∑yn) the data for which is inserted below into molecular formula IMg1- xFex(OH)2][(CO3)y1(SO4)y2 mH2O] [Na2SO4J2
Example 1
Prepared by the method described below for preparation of approximately 250 gram of dried product targeted to have a Mg:Fe molar ratio of 1 :1.
The actual molecular formula found by analysis was:
[Mg0 5Fe0 5(OH)2][(CO3)0 ,4(SO4)002-0 4H2O][Na2SO4]D oo
Wherein x = O 5, y1 = O 14, y2 = O 02, m - 0,4, z = O Two starting materials, designated solution 1 and solution 2 were prepared by the method set out below such as to provide an Na2CO3 excess of 2 7 mole (in reaction equation 1).
Magnesium sulphate and iron sulphate were dissolved in AnalaR™ water to prepare solution 1. in a separate vessel sodium carbonate and sodium hydroxide were dissolved in AnalaR™ water to prepare solution 2 The weights used were calculated to give the desired ratio of metal cations For the preparation of solution 1 , AnalaR™ water was weighed out into a vessel and stirred using an overhead mixer, into which was dissolved an appropriate amount of ferric sulphate hydrate (GPR grade) Once dissolved, magnesium sulphate (Epsom Salt) was quantitatively transferred to the stirred iron sulphate solution and allowed to dissolve.
For the preparation of solution 2, AnalaR™ water was weighed out into a vessel and stirred using an overhead mixer, into which was dissolved an appropriate amount of sodium carbonate (Pharmakarb). Once dissolved, sodium hydroxide (Pearl Caustic Soda) was quantitatively transferred to the stirred sodium carbonate solution and allowed to dissolve
The solutions were then added simultaneously to stirred heel water of 1100 cm3 at controlled flow rates sufficient to maintain pH 10.3 in the reaction mixture (+/- 0 2 pH units) at a reaction temperature not exceeding 3O0C The final slurry concentration was around 5.1 wt% compound
When the additions were complete, the reaction mixture was mixed for another 30 minutes and then filtered using a buchner filtration set up The product slurry was filtered using a vacuum pump and buchner funnel with a Whatman™ hardened ashless filter paper (No 541) After filtering, the filter cake was washed with portions of AnalaR™ water. The filtered product was then washed with 220 cm3 portions of cold AnalaR™ water After isolation the product was dried using a preheated oven.
A weight of AnalaR™ water was placed into a vessel. Flow control units were used to deliver the appropriate flow rates of the alkaline carbonate and metal sulphate solutions
After isolation the washed product was transferred to a vessel and dried in a preheated oven at 1200C for three hours.
Product sample for analysis were ground using a bail mill (Retsch PM 100) The milling parameters were set depending on the properties of the product. Product sample for analysis was milled through a stainless steel, 200mm diameter, 106μm sieve, using a sieve shaker (Retsch AS-200) Oversize material was returned to the stock dried sample to be reground, until all materia! is < 106 μm Example 2
Preparation method as for Example 1 but targeted to have a Mg. Fe molar ratio of 2:1
The actual molecular formula found by analysis was.
[Mg054Fe036(OH)2l[(CO3)y1(SO4)003 0 20H2O][Na2SO4]z
Example 3
Preparation method as for Example 1 but targeted to have a Mg:Fe molar ratio of 3.1.
Example 4
Preparation method as for Example 1 but targeted to have a Mg: Fe molar ratio of 4: 1 Example 5 & 6 [intentionally blank]
Example 7
Preparation method as for Example 1 but targeted to have a Mg:Fe molar ratio of 2: 1 and intended ageing (increase in crystallite size) by introducing an additional method step immediately after precipitation wherein the reaction slurry is aged by heat treatment The slurry is refluxed for 4 hours by using a hot plate and a Liebig condenser to reflux the sample in a sealed flask. The sample was then immediately filtered using a Buchner funnel under vacuum The aged compound was then isolated using the same method as described for Example 1
The actual molecular formula found by analysis was:
[Mgo66Feo34(OH)2][(C03)y,(S04)0 01 0 09H2O][Na2SO4]z Example 8-24
Preparation method as for Example 2 but with a liquid ferric source of 40 4 to 42 9 wt% ferric sulphate of water industry standard suitable for human consumption conforms to BS EN 890 2004) The method was then varied in that they were conducted at different precipitation pH, different excess of Na2CO3, and different reaction temperature i e either unaged (i e at relatively low reaction temperature 15, 30 or 65 Celsius) or aged (at 90 Celsius) according to examples described beiow Where the examples were unaged either the solutions were cooled (to 15 Celsius) or no heat-treatment of reaction slurry occurred (at 30 Celsius) or some gentle heating (at 65 Celsius); whereas when aged, heat-treatment of the reaction slurry occurred by using a sealed glass beaker with condenser placed on a hotplate and reaction slurry heated at 90 0C for 4 hours) Where a reaction temperature is not mentioned the reaction was conducted at the standard room temperature of approximately 25-30 Celsius, The reaction slurry was cooled to 15 Ceisius by placing the metal beaker in an ice water bath; the temperature was monitored by a thermometer and controlled by the addition and removal of ice The reaction slurry was heated to 65 Celsius by placing the metal beaker in a thermostatically controlled water bath Grant W38 The temperature was monitored by a thermometer The reaction slurry conducted at 30 Celsius started at room temperature but gradually rose to a final temperature of 30 Ceisius after addition of the reagents After the addition of the reagents the slurry was mixed for 30 minutes before filtration with the exception of example 21 which was mixed for 960 minutes.
The actual molecular formula determined by analysis, crystallite size, precipitation pH, slurry treatment, excess moles of Na2CO3 in recipe are fisted below for each example. Results of examples 8-24 are shown in Table 3 and Figure 1
Example 8 [Mg02Fe0 B(OH)2][(CO3)016<SO,)00 0 42H2O] [Na2SO4J0 oo
Crystallite size: not determined (nd)
Precipitation pH = 8 0, reaction temperature is 30 Celsius: 2 7 moles excess Na2CO3 9 [Mg0 sFeQ s(OH)2][(CO3)0 i4(S04)o o2 0 39H2O] [Na2SO4J0 QD
Crystallite size: > 200 A Precipitation pH = 9 8, reaction temperature is 90 Celsius, 2 7 moles excess Na2CO3
[Mg05FeD 5(OH)2][{CO3)0 u(SO4)002 0 39H2O] [Na2SO4J000
Crystallite size: > 200 A
Precipitation pH = 9 8; reaction temperature is 90 Celsius; 4 moles excess
Na2CO3 [Mg067Feo 3B(OH)2][(CO3)0 14(SO4)001.0.23H2O] [Na2SO4Jo 00
Crystallite size, not determined (nd)
Precipitation pH = 10 1 , reaction temperature is 650C; 2 7 moles excess
Na2CO3 [Mg0 B7Fe033(OH)2If(COS)0
Figure imgf000056_0001
01-0.25H2O] [Na2S04]00o
Crystallite size, not determined (nd)
Precipitation pH = 9 8; reaction temperature is 650C; 2 7 moles excess
Na2CO3 [Mg067Fe033(OH)2][{CO3)0 w(SO4)001 O 39H2O][Na2SO4J0 00
Crystallite size: not determined (nd)
Precipitation pH = 1 1 ; reaction temperature is 30 Celsius, 4 moles excess
Na2CO3 [Mg0 BsFe034(OH)2][(C03)o i5(SO4)002 O 39H2O] [Na2S04]00o
Crystallite size: not determined (nd)
Precipitation pH = 10 5; reaction temperature is 30 Celsius; 2 7 moles excess Na2CO3 [Mg065Fe0 34(OH)2K(CO3)014(SO4)O O2 O 23H2O] [Na2S04]0oo
Crystallite size, not determined (nd)
Precipitation pH = 10 3, reaction temperature is 30 Celsius, 2 7 moles excess Na2CO3 [Mg067Fe033(OH)2]I(CO3)O i3(SO4)002 O 73H2O] [Na2SO4]0 00
Crystallite size, not determined (nd)
Precipitation pH = 10 5; reaction temperature is 30 Celsius; 1 moles excess Na2CO3 [Mg06/Fe033(OH)2][(CO3)013(SO4)α 02.0.38H2O] [Na2SO4J0 oo
Crystallite size' not determined (nd)
Precipitation pH = 10.1 ; reaction temperature is 30 Celsius; 2 7 moies excess Na2COa [Mg0 6SFe0 34(OH)2][(C03)o iβ(S04)o 02 O 37H2O) [Na2SO4Jo oo
Crystallite size: <100 A
Precipitation pH = 9 8; reaction temperature is 30 Celsius 2 7 moles excess Na2CO3 [Mg066Fe034(OH)2][(CO3)α i2(Sθ4)Q 03. 0.65H2O][Na2SO4]O
Crystallite size: not determined (nd)
Precipitation pH = 9,8; reaction temperature is 30 Celsius; 4 moles excess Na2CO3 [Mg0 βrFe033(OH)2][(CO3)Q i3(S04)o os-0 38H2O] [Na2SO4]O oo
Crystallite size: not determined (nd)
Precipitation pH = 11; reaction temperature is 15°C; 1 moles excess Na2CO3 [Mg064Fe036(OH)2H(CO3)O 12(SO4)O O3.ndH2O] [Na2SO4Jo oo
Crystallite size: not determined (nd)
Precipitation pH = 9.6; reaction temperature is 30 Celsius; 2 7 moles excess Na2CO3 [Mg0 B4Fe0 36(OH)2][(C03)o i_(SO4)0 O4-O 56H2O] [Na2SO4J0 oo
Crystallite size: not determined (nd)
Precipitation pH = 9 5; reaction temperature is 30 Celsius; 2,7 moles excess Na2CO3 [Mg062Fe0 38(OH)2][(C03)0 12(Sθ4)o 04 0.49H2OPa2SO4J00O
Crystallite size- not determined (nd)
Precipitation pH = 9.5; reaction temperature is 30 Celsius; 4 moles excess Na2CO3 23 [Mg064Fe03B(OH)2]KCO3)O 12(SO4),, 04 0 52H2O][Na2SO4J0 oo Crystallite size: not determined (nd)
Precipitation pH = 9 5, reaction temperature is 30 Celsius, 1 moles excess Na2CO3
24 Mg0 5BFe042(OH)2K(CO3)O i(SO4)O o5 O 43H2Oj[Na2SO4]O o0
Crystallite size: not determined (nd)
Precipitation pH = 9 5; reaction temperature is 150C; 1 moles excess Na2CO3
Example 25-27
Preparation method and Mg:Fe ratio as for Example 2 with a ferric source of 40 4 to 42 9 wt% ferric sulphate of water industry standard suitable for human consumption conforms to BS EN 890:2004 and with precipitation pH varied in accordance with Table 4 and filtered
Example The actual molecular formula found by analysis was:
25 [Mgo6sFeo35(OH)2][{C03)y,(S04)y2 mH20] [Na2SO4J0 G0
26 [Mg0 G5Fe035(OH)2l[(CO3)yl(SO4)y2 mH2O][Na2SO4]z
27 [Mg06.Fe035(OH)2][(CO3)013(SO4)D D2 mH2Oj [NazSO4]0 oi
Example 28 To make 163 kg of the mixed metal compound (dry basis) two starting solutions were prepared designated solution A and solution B To prepare solution A, 138 kg (dry basis) iron sulphate of 40.4 to 42 9 wt% ferric sulphate of water industry standard suitable for human consumption conforms to BS EN 890:2004, 166 kg (dry basis) magnesium sulphate (added as the hepta-hydrate) were dissolved in a total of 1034 kg of water where this total water amount includes the water associated with the ferric sulphate solution. To prepare solution B, 173 kg sodium hydroxide and 129 kg sodium carbonate were dissolved in 948 kg of water to provide homogenous solutions. The reaction vessel water heel was 840 kg The water supplied to the heel was 30% of the total water supplied The reactant solution temperatures are adjusted to around 22°C prior to addition The reactant streams (solutions A and B) are then simuitaneously fed to the reaction vessel at a rate such as to maintain a reaction pH of 9 8. Cooling of the vessel contents is applied such as to maintain a temperature of 20-25 0C. A heel of purified water is introduced prior to the introduction of the reactant streams in order to enable agitation of the vessel in the initial reaction phase and to give a final slurry concentration of around 5 1 wt% compound
The vessel is agitated using a high turnover, low shear axial flow agitator operating at a power per unit volume of 0,1 kW/rn3 and where the reactant solutions are delivered to an area of high turnover The reactor is baffled in order to promote good mixing
The precipitate slurry is held in the reaction vessel (also referred to as hold time) for up to 12 hours and is transferred in aliquots to a vertical filtering centrifuge for isolation and washing, using purified water so as to provide maximum product rate. Washing is terminated to achieve a residua! sodium content (expressed as Na2O in the dried product) of less than 0 40 wt%.
The wet cake is discharged from the centrifuge and is dried in a spherical, agitated vacuum drier Vacuum and shell temperature are adjusted to provide a product temperature in the dryer of approximately 72°C The rate of drying was 0 26 kg water/(kg dried product hr) a residence time of 12 hours and a product rate per unit area of 4 6 kg product /(m2 hr) The dried product is first coarse milled using a de-lumptng mill to a particle size distribution (Test Method 24) of typically 200 micron (D50) followed by final micronisation to a particle size of typically 5 micron (D50).
Example The actual molecular formula found by analysis was'
28 [Mg0 eeFeα 34(OH)2]I(CO3)O i2(S04)o 03 0.20H2O] [Na2SO4]G 00
Example 28b
Particle size distribution was measured in the reaction slurry after the addition of the reagents and after a hold time of 4 hours and filtration rate measured during the isolation step Example 28c - Alternative Reaction Systems
CFD (Test Method 27) was applied to example 28 in order to derive a mixing power per unit volume at the point of addition of the reactant streams
The calculations were based on system having.
Slurry density. 1200 kg.m~3
Slurry viscosity. 20 cP {0 02 Pa s)
Agitator Shaft speed: 100 rpm
Baffling: Flat plates
The pattern of mixing is demonstrated via particle tracks from each of the two reactant stream inlets and shows that the streams remain effectively segregated from each other before the fluid has dispersed widely into the butk Contours of concentration were also generated and confirm that mixing into the bulk takes place very rapidly,
To derive the requirements for the manufacture of mixed metal compounds for alternative mixing systems (e g. static mixers), the findings for the conventional low shear agitated system (described above) have been applied.
Alternative mixing systems such as static mixers, jet mixers, or dynamic in-line mixers and in particular a Kenics KM static mixer may be suitable to provide a volume in which the reaction can take place and suitable to deliver the necessary mixing regime For example the Kenics KM static mixer using a notional feed zone volume of SxIO"4 m3, to provide a power to mass ratio (1 28 W/kg - equivalent to 154 kW/m3) and residence time (1 25 sec) The length was fixed by the recommended minimum length of 4 elements (hence L/D=6), The resulting diameter was 100 mm and the flowrate 280 litre/min.
To summarise, for a conventionally agitated reaction systems a power per unit volume range (mixing intensity) of 0 03 to 0 5 kW/m3 has been established as optimum. Using alternative mixing equipment, a power per unit volume range (mixing intensity) of 0.03 to 1.6 kW/m3 has been established as optimum
Example 29
As for example 28 but with a reaction pH of 10.3. Example 30
As for example 28 but with a batch size of 7 kg using a single-aliquot feed to the Neutsch filter instead of centrifuge such that the reaction mass is isolated and washed within a time period of no more than 16 hours, a tray oven instead of a spherical drier and milled
The wet cake is discharged from the Neutsch filter and is dried in a vacuum tray oven where the oven wails are heated to 120 to 1300C and regular manual redistribution of the drying mass is carried out The rate of drying was 0 38 kg water/{kg dried product hr) with a total drying time of 12 to 16 hours and a product rate per heated dryer surface area of 0,2 kg product /(m2 h)
The dried product is micronised using an impact mill to a particle size of typically 5 micron <D50, Test Method 24).
Example The actual molecular formula found by analysis was"
30 [Mg065Fe035(OH)2][(CO3)Q 11(SO4),a 0 49H2O] [Na2SO4]z Example 31
As for example 30 but with a reaction pH of 10 3
Example The actual molecular formula found by analysis was- 31 [Mg066Fe034(OH)2K(CO3)O i2(S04)o 02 0 28H2O] [Na2SO4]Q0
Example 32
As for example 28 but with a Vacuum Beit filter instead of centrifuge.
Samples of wet cake discharged from the Vacuum Belt filter were dried in the laboratory oven at 120°C for three hours
Product sample for analysis were ground using a ball mill to allow it to pass through a 106μm sieve. Example 33
A reaction slurry was prepared according to the method of example 2 but with a reaction pH of 9 6, a liquid ferric source (a solution 40.4 to 42,9 wt% ferric sulphate of water industry standard suitable for human consumption conforms to BS EN 890:2004) and a nominal 400 cm3 batch size. The reaction slurry was washed using Tangential Flow Filtration (Sartorius Slice 200 bench top system with 200 cm2 filtration area, PESU 0 1 micron membrane) operated in constant rate mode The system was flushed and filled with Dl water prior to filtration, the permeate rate was regulated to prevent filter blockage Filtration with wash water addition (diafiltration) was carried out to achieve a residual sodium content (expressed as Na2O in the dried product) of less than 0.40 wt%. The washed slurry was then concentrated using conventional vacuum filtration and dried in a laboratory oven. Example The actual molecular formula found by analysis was.
33 [Mg0 6SFe03s(OH)2][(CO3)y, (SCUV ^H2O] [Na2SO4]z
Example 34 As for example 33 but with a reaction pH of 10 1 Example 35
As for example 33 but with a reaction pH of 10 3,
Example The actual molecuiar formula found by analysis was.
35 [Mg0 S5Fe035(OH)2][(CO3)yl(SO4)y2 mH2O] [Na2SO^
Example 36
A reaction slurry was prepared for processing according to the method of Example 28, However, 620 kg of reaction slurry were subsequently processed using Tangential Flow Filtration instead of centrifugatϊon A reaction pH of 9,8 was used. Prior to filtration, to reduce the risk of membrane blockage, the reaction slurry was circulated through a wet colloid mill in order to reduce the D50 particle size (Test Method 9) from 60 to 51 micron A Sartorius Sartoflow Beta filtration unit was used with eleven Sartocon Il membranes giving a total filtration area of 7 7 m2 The system was flushed and filled with Dl water prior to filtration, the permeate rate was regulated to prevent filter blockage A rotary lobe pump was used to circulate slurry through the system at an inlet pressure of between 2 and 3 5 bar and a typical retentate flow of 3400 l/h Filtration with wash water addition (diafiltration) was carried out until to achieve a residual sodium content (expressed as Na2O in the dried product) of less than 0 40 wt%
A representative quantity of slurry was sampled and isolated and dried in accordance with the method of Example 1 but without additional cake washing
Example 37
As for example 36 but with a reaction pH of 10 3. The particle size (D50, Test Method 9) was reduced by wet milling from 47 to 44 micron
Example 38
As for example 28 but the method was then varied in that they were conducted with slightly different drying conditions. The rate of drying was approximately 0 27 kg water/(kg dried product hr), a residence time of 13 hours, a product rate per unit area of 1 4 kg product /(m2 hr), and the maximum dryer temperature achieved is approximately 85 0C
Example The actual molecular formula found by analysis was
38 [Mg06eFe034(OH)2}[(CO3)0 i 3(S04)o D3 0 36H2O] [Na2SO4J0 oo
Example 39
As for example 28 but the method was then varied in that they were conducted with different drying conditions. The rate of drying was approximately 0 38 kg water/(kg dried product.hr), a residence time of 9 hours and a product rate per unit area of 1.2 kg product /(m2 hr).
Example The actual rnoiecular formula found by analysis was;
39 [Mg067Fe033(OH)2]E(CO3)O i3(SO4)QOa O 26H2O]-[Na2SO4IQ 0O
Example 40
As for example 30 but the method was then varied in that they were conducted with different drying conditions. The rate of drying was approximately 0.21 kg water/(kg dried product.hr) a residence time of 18 hours and a product rate per unit area of 0 1 kg product /{m2..hr)
Example 41
As for example 30 but the method was then varied in that they were conducted with different drying conditions. The rate of drying was approximately 0,27 kg water/(kg dried product.hr) a residence time of 16 hours and a product rate per unit area of 0.2 kg product /(m2 hr)
Example The actual molecular formula found by analysis was:
41 [Mg0 BeFe034(OH)2]I(CO3)O I3(SO4)O 02.mH2O] [Na2S04]00o
Example 42-47
As for example 28 but the method was then varied in that they were conducted with different drying conditions as described in Table 7 when dried with a spherical, agitated vacuum drier (long residence dryer) Example The actual molecular formula found by analysis was:
43 [Mg066Fe034(OH)2]I(CO3)O i3(SO4)G 02.0 53H2OJ]Na2SO4Io 01
44 [Mg065Fe03S(OH)2][(C03)o i2(SO4)G 03. mH2O], [Na2SO4]000
45 [Mg067Fe0 33(OH)2]I(CO3)O I3(SO4)O [Na2SO4]O Q0
46 [Mg0 ββFeo 34(OH)2][(C03)o «(S04)o 03, 0.29H2O] [Na2S04]00o
47 [Mg065Fe0 35(OH)2][(CO3)0 13(SO4)003 mH20] [Na2SO4]0 QO Example 48-49
As for example 28 (centrifugation) but the method was then varied in that the filter-cake was dried using a short residence type drier (Spin-Flash Drier, manufacturer/ mode!; Anhydro/ SFD51) wherein the delta T was 0.40 (Example 48) or a delta T of 0 66 (Example 49)
Conditions spray drier
Example T8n (0C) T0Ut (0C) delta T Rotor Product
speed (%) rate (kg/h)
48 250 150 0 40 90 8
49 350 120 0 66 45 20
Delta T = (Tin - Tom) / Tin
Example The actual molecular formuia found by analysis was-
48 [Mg0 B5Fe035(OH)23[(C03)o i5(S04)o 02 0 19H2O][Na2SO4]Q00
49 [Mg0 BeFe0 34(OH)2][(CO3)0 u(SO_,)o 02 0 16H2O][Na2SO4]0 D0 Example 50
As for example 36 (tangential flow filtration) but the method was then varied in that the slurry was dried using a short residence type drier (Spray Drier, manufacturer/ model; Anhydro/ CSD71) with a delta T of 0.69
Conditions spray drier
Example Tin (0C) T0Ut (αC) deita T Tip speed (Hz)
50 350 110 0 40 208.3 Deita T = (T|π - Tout ) / Tin
Example The actual molecular formuia found by analysis was:
50 [Mg066FeD 34(OH)2][(CO3)0 i4(SO4)002 0 37H2O][Na2SO4Io 01 Example 51- 52
As for example 28 (centrifugation) but the method was then varied in that the filter-cake was first diluted to provide a 10 1 wt% slurry and then dried using a short residence type drier (Spray Drier, manufacturer/ model, Anhydro/ CSD71 ) wherein the delta T was 0.74 (Example 51 ) or a delta T of 076 (Example 52)
Conditions spray drier
Example Tfπ (0O T0Ut (0C) delta 1 Tip speed (Hz)
51 350 110 0 74 208.3 Hz
52 325 120 0,76 208.3 Hz
Example The actual molecular formula found by analysis was:
51 [Mg066Fe0 34(OH)2]E(CO3)D 14(SO4)(J 01 0 34H2O][Na2SO4] 001
52 [MgD 65Feo 35(OH)2][(C03)0
Figure imgf000066_0001
o3 0 38H2O)[Na2SO4] 0 00
Example 53-59
As for example 28 (centrifugation) but the method was then varied in that instead of micronisation the dried product was only coarse-milled to 343 micron (μm) (D50) and hereafter separated into 6 different particle size fractions by sieving, Six different sieves were used with a sieve parameter size of respectively; base, 20 micron, 75 micron, 106 micron, 180 micron, 355 micron. The sieve fractions were obtained by hand-sieving, The
6 different sieve fractions (Example 53-58) obtained by this method are described in Table 9,
Example The actual molecular formula found by analysts was:
53 [Mgo65Fe0 3s(OH)2][(Cθ3)yi(Sθ4)oQ3..mH20] [Na2S04]00o
Sieve fraction: > 355 μm
54 [Mgo65Fe035(OH)2][(C03)yl(Sθ4)0 o3.mH20].[Na2S04]0 Qo
Sieve fraction: 180 - 355 μm
55 [Mg065FeD 35(OH)2][(CO3)y1(SO4)0 Q3,mH2O].[Na2SO4]0 00
Sieve fraction: 106 - 180 μm
56 [Mg065Fe035(OH)2][(CO3)y1 (SO4).03 mH2O], [Na2SO^]0 Oo
Sieve fraction: 75 - 106 μm
57 [Mg0 S5Fe035(OH)2][(CO3)y1 (S04)o 03 mH20] [Na2S04]G Oo Sieve fraction" < 106 μm
58 [Mg0 B5Fe035{OH)2][(C03)yi{Sθ4}o 03 mHaO] [Na2SO4]QQ0
Sieve fraction' < 20 μm
59 [Mg06sFe0 34(OH)2][(C03)o i2(SO4)0 03 0 26H2O] [Na2SO4]Q 00
micfonised
Example 60
As for example 28 but the method was then varied in that they were conducted with different drying conditions The rate of drying was approximately 0 33 kg water/(kg dried product hr), a residence time of 9 8 hours and a product rate per unit area of 1 6 kg product /(m2 hr) and the maximum dryer temperature achieved is approximately 76 0C
Exampie The actual molecular formula found by analysis was:
60 [Mg066FeO35(OH)2]I(CO3)O 12(SO4)Oo3 mH20] [Na2SO4]DQQ
Example 61
As for example 28 but the method was then varied in that they were conducted with different drying conditions The rate of drying was approximately 0 28 kg water/(kg dried product hr), a residence time of 10 3 hours and a product rate per unit area of 1 5 kg product /(rn2 hr) and the product temperature achieved is approximately 64 0C
Exampie The actual molecular formula found by analysis was:
61 [Mg06SFe0 34(OH)2][(CO3)0 13(SO4)0 03 mH20] [Na2SO4]0 00
Example 62-65
As for Example 2 but the method was then varied in that they were conducted at different pH, different excess of Na2CO3 and different ferric source in accordance with Table 12.
Furthermore, Example 62 was prepared with aluminium sulphate in place of iron sulphate
Two different ferric source designated A and B were used:
A: of GPR grade Rectapur
B: a more pure ferric source such as a solution 40 4 to 42 9 wt% ferric sulphate of water industry standard suitable for human consumption conforms to BS EN 890 2004, Example The actual molecular formula found by analysis was:
62 [Mg0 73Ai0 21 (OH)2][(C03)o 16(SO,)oo2.mH20]. [Na2SO^]0 Q0
63 [Mg0 66Fe0 34(OH)2][(CO3)0 14(SO4)002 O 22H2O] [Na2SO4Jo 00
64 [Mg0 66Fe0 34(OH)2][(CO3)y1 (SO4)0 02 mH20] [Na2SO4]0 00
65 [Mg066Fe0 34(OH)2][(CO3)y1 (S04)G 01 mH20], [Na2SO4]D oα
Example 66
As for example 28 but the method was then varied in that the filter-cake was dried using a short residence type drier (Spin-Fiash Drier, manufacturer/ model; Anhydro/ SFD51) wherein the delta T was 0,48 Conditions spin flash drier
Example Tm (0C) T0Ut(°C) delta T Atomiser speed , Hz
66 250 130 0 48 90
Delta T = (Tιn - Tout) / T1n
Example The actual molecular formula found by analysis was.
66 [Mg0 B5Fe035{OH)zl[(CO3)0 n(S04)o 03.0.31 H2O] [Na2SO4J0
METHODS
Test Method 1 XRF Analysis
XRF analysts of the product was performed by using a Philips PW2400 Wavelength Dispersive XRF Spectrometer, The sample was fused with 50:50 lithium tetra/metaborate (high purity) and presented to the instrument as a glass bead All reagents used were analytical grade or equivalent unless specified. AnalaR™ water, Lithium tetraborate 50% metaborate 50% flux (high purity grade ICPH Fluore-X 50). A muffle furnace capable of 1025 0C, extended tongs, hand tongs, Pt/5%Au casting tray and Pt/5%/Au dish were used. 1 5 g (+/- 0.0002 g) of sample and 7.5000 g (+/- 0.0002 g) of tetra/metaborate was accurately weighed out into a Pt/5%/Au dish. The two constituents were lightly mixed in the dish using a spatula, prior to placement in the furnace preset to 1025 0C for 12 minutes The dish was agitated at 6 minutes and 9 minutes to ensure homogeneity of the sample Also at 9 minutes the casting tray was placed in the furnace to allow for temperature equilibration After 12 minutes the molten sample was poured into the casting tray, which was removed from the furnace and allowed to cool The bead composition was determined using the spectrophotometer
The XRF method was used to determine the Al, Fe, Mg, Na and total sulphate content of the compound as well as the Mil to Mill ratio Test Method 2 X-Ray Diffraction (XRD) measurements
Data was collected for fine particulate samples from 2-70° 2Θ on a Philips automatic powder X-ray diffractometer using Copper K alpha radiation generated at 4OkV and 55mA
Powder X-ray diffraction (XRD) data were collected from 2-70 degrees 2theta on a Philips PW 1800 automatic powder X-ray diffractometer using copper K alpha radiation generated at 4OkV and 55mA, a 0 02 degree 2theta step size with a 4 second per step count time, An automatic divergence slit giving an irradiated sample area of 15 x 20mm was used, together with a 0 3mm receiving slit and a diffracted beam monochromator
The approximate volume average crystallite size can be determined from the width, at half peak height, of the powder X-ray diffraction peak at about 11.5 degrees 2 theta (the peak is typically in the range 8 to 15 degrees 2 theta for hydrotatcite type materials) using the relationship given in Table 1 which is derived using the Scherrer equation The contribution to the peak width from instrument line broadening was 0 15 degrees, determined by measuring the width of the peak at approximately 21 4 degrees 2theta of a sample of LaB5 (NIST SRM 660) under the same conditions Table 1 XRD Peak width conversion to crystallite size using the Scherrer equation
Figure imgf000070_0001
Figure imgf000071_0001
The values in Table 1 were calculated using the Scherrer equation:
D = K * Λ / β * cos© Equation 1 Where.
D = crystallite size (A)
K = shape factor
λ = wavelength of radiation used (in A)
β = peak width measured as FWHM (full width at half maximum height) and corrected for instrument line broadening (expressed in radians)
Θ = the diffraction angle (half of peak position 2Θ, measured in radians) Shape factor
This is a factor for the shape of the particle, typically between 0 8 - 1 0, a value of 0 9 is used
Wavelength of radiation
This is the wavelength of the radiation used For copper K alpha radiation the value used is 1 54056 A,
Peak width
The width of a peak is the sum of two sets of factors, instrumental and sample.
The instrumental factors are typically measured by measuring the peak width of a highly crystalline sample (very narrow peaks) Since a highly crystalline sample of the same material is not available, LaB6 has been used For the current measurements an instrument value of 0 15 degrees has been used
Thus for the most accurate measure of crystallite size using the Scherrer equation, the peak width due to instrumental factors should be subtracted from the measured peak width i e : p "~ ^(measured) ~ b(jnstrumental)
The peak width is then expressed in radians in the Scherrer equation
The peak width (as FWHM) has been measured by fitting of a parabola or another suitable method to the peak after subtraction of a suitable background Peak position
A value of 11.5 °2Θ has been used giving a diffraction angle of 5 75 ° Corresponding to 0 100 radians Test Method 3 Phosphate Binding Capacity and Mq Release
Phosphate buffer (pH = 4) was prepared by weighing 5 520 g (+/-0 001 g) of sodium di- hydrogen phosphate followed by addition of AnalaR™ water and transferring to a 1 ltr volumetric flask
To the 1 litre volumetric flask was then added 1 M HCI drop-wise to adjust the pH to pH 4 (+/-0 1) mixing between additions The volume was then accurately made up to 1 ltr using AnalaR™ water and mixed thoroughly
0 5g (+/- 0 005g) of each sample was added to a volumetric flask (50ml) containing 4OmM phosphate buffer solution (12.5ml) at 37 50C in a Grant OLS 200 Orbital shaker. AIi samples were prepared in duplicate. The vessels were agitated in the orbital shaker for 30 minutes The solution was then filtered using a 0 45 μm syringe filter. 2 5 cm3 aliquots of supernatant were pipetted of the supernatant and transferred into a fresh blood collection tubes 7,5 cm3 of AnalaR™ water were pipetted to each 2.5 cm3 aliquot and the screw cap fitted and mixed thoroughly The solutions were then analysed on a calibrated ICP-OES.
The phosphate binding capacity was determined by:
Phosphate binding (rnmo!/g) = SP (mmol/l) - TP (rnmol/l) / W (g/l) where.
Tp = Analyte value for phosphate in the phosphate solution after reaction with phosphate binder = solution P (mg/l) * 4 / 30 97.
Sp = Anaiyte value for phosphate in the phosphate solution before reaction with phosphate binder.
W = concentration binder (g/i) used in test method (i e 0.4 g / 10 cm3 = 40 g/l)
Magnesium release was determined by- Magnesium release (mmol/g) =TMg (mmol/l) - SMa (mmol/i) / W (g/l) where- Tiwg = Aπaiyte value for magnesium in the phosphate solution after reaction with phosphate binder =. solution Mg (mg/l) * 4 / 24.31.
SMg - Anaiyte vaiue for magnesium in the phosphate solution before reaction with phosphate binder
Fe release was not reported as the amount of iron released from the compound was too small and below detection limit
Test Method 4 Phosphate, Binding and MagOssium Release in Food Slurry,
MCT peptide2+, food supplement (SHS International) was mixed to form a slurry of 20% (w/v) in 0 01 M HCi Separate aliquots of 0 05 g dry compound were mixed with 5 cm3 of the food slurry and constantly agitated for 30 minutes at room temperature A 3 cm3 aliquot was removed and centrifuged at 4000 rpm for 10 minutes, and the phosphate and magnesium in solution were measured.
Test Method 5 Sulphate Determination
Total sulphate in the compound
Sulphite (SO3) is measured in the compound by XRF measurement (Test Method 1) and expressed as total sulphate (SO4) according to:
Total SO4(wt%) = (SO3) x 96/80
Total SO4 (mole) = total SO4 (wt%) / molecular weight SO4
Sodium Sulphate (soluble form of sulphate present in the compound)
Na2O is measured in the compound by XRF measurement (Test Method 1)
It is assumed that the Na2O is associated with the more soluble form of SO4 in the form of Na2SO4 present in the compound.
Consequently, the number of mole Na2O is assumed equal to that of soluble form of sulphate and is therefore calculated as:
soluble SO4 (mole) = Na2O (mole) = wt% Na2O / molecular weight Na2O lnteriayer sulphate (insoluble form of sulphate present in the compound also referred to as bound sulphate) The interlayer sulphate is calculated according to- interlayer SO4 (mole) = total SO4 (moie) - soluble SO4 (mole)
interlayer SO4 (wt%) = interlayer S04 (mole) x molecular weight S04
Test Method 6 Carbon Content Analysis by the Leco Method
This method was used to determine the levels of carbon content (indicative of the presence of the carbonate anion present in the mixed metal compound)
A sample of known mass is combusted at around 1350 °C in a furnace in a pure oxygen atmosphere Any carbon in the sample is converted to CO2 which is passed through a moisture trap before being measured by an infra-red detector By comparing against a standard of known concentration, the carbon content of the sample can be found A Leco SC-144DR carbon and Sulphur Analyser, with oxygen supply, ceramic combustion boats, boat iance and tongs was used 0 2 g (+/-0.01 g) of sample was weighed into a combustion boat. The boat was then placed into the Leco furnace and the carbon content analysed The analysis was performed in duplicate
The % C was determined by
%C (sample) = (0ZoC1 + %C2)/2
Where Ci and C2 are individual carbon results
The results of the carbon content measurements are seen in Table 3 and Figure 1 and were expressed as %CO2 = %C x 44/12
Test Method 7 Wash Time
Wash time was measured in minutes rounded to the nearest minute, it was the time it took for one wash (i e one wash volume of water) to be drawn through the filter The wet cake was not allowed to dry or crack during this period The time was measured using a stop clock Test Method 8 Filtration Time (Lab scale)
Filtration time was measured in minutes rounded to the nearest minute, it was the time taken for the slurry to be drawn through the filter, but the resulting wet cake was not allowed to dry. The time was measured using a stop clock.
Test Method 9 Particie Size Distribution (PSD) by Lasentech
In process particle size distribution in the slurry was measured using a Lasentech probe The d50 average particle size, is obtained as part of this analytical technique.
Test Method 10 Filtration Rate fml/min)
Defined as the quantity of filtrate obtained in a given time
Test Method 11 F i itrati o n Rate, {kg, dry, ,p roducj/m^.h)
Filtration Rate {kg dry product/m2 h) is defined as the mass of wet cake, expressed as dried compound, isolated, washed, dewatered and discharged per hour, divided by the area of filter used.
Test Method 12 Moisture Content
The moisture content of mixed metal compound is determined from the loss of weight (LOD) foliowing drying at 105'C for four hours at ambient pressure in a laboratory oven
Test Method 13 flntentionaliv Left Blanki
Test.Method.,.14 Surface Area and Pore Volume (Nitrogen Method -N?)
Surface area and pore volume measurements were obtained using nitrogen gas adsorption over a range of relative pressures using a Micromeritics Tristar ASAP 3000. The samples were outgassed under vacuum for 4 hours at 1050C before the commencement of measurements. Typically a vacuum of <70mTorr was obtained after outgassing. Surface areas were calculated by the application of Brunauer, Emmett and Teller (BET) theory using nitrogen adsorption data obtained in the relative pressure range of 0.08 to 0.20 PIPo.. Pore volume was obtained from the desorption loop of the nitrogen adsorption isotherm, using the volume of gas adsorbed at a relative pressure (P/Po) of 0 98. The quantity of gas adsorbed at 0.98 relative pressure (in cc/g at STP) is converted to a liquid equivalent volume by multiplying by the density conversion factor of 0.0015468 This gives the reported pore volume figure in cm3/g.
P = partial vapour pressure of nitrogen in equilibrium with the sample at 77K
Po = saturated pressure of nitrogen gas
Test Method 15 Pore Volume (water method) Water Pore Volume
Aim
To fill internal pores of a sample (in powder form) with water such that, when all the pores are filled, the surface tension of the liquid causes the majority of the sample to form an aggregate which adheres to a glass jar on inversion of the jar.
Equipment
(1) Wide neck (30mm) clear glass 120 cm3 powder jar with screw cap. Dimensions* Height 97mm. Outer Diameter 50mm (Fisher part number BTF-600-080)
(2) 10 cm3 Grade A burette
(3) Deionised water
(4) Rubber bung 74mm diameter top tapered to 67mm. Overall height 49mm
(5) Calibrated 4 decimal place balance
Procedure
(1) a 5.0Og (±0.01) sample in the glass jar, add a 1 cm3 aliquot of water
(2) After this addition vigorously knock the bottom end of the sealed jar against the rubber bung 4 times.
(3) Using a sharp swing of the arm, flick the jar with the wrist to invert the jar and check the sample:
a If the sample agglomerates and the majority (>50%) of the sample adheres to the jar this is the end point (go to results section below). If free water is observed with the sample, the end point has been exceeded and the test should be discarded and started again with a new sample, b If the sample dislodges from the jar {even if agglomeration is evident), add a further 0.1 cm3 of water and repeat steps (2) to (3) above until the end point is reached(3a))
Results
The water pore volume is calculated as follows. -
Water Pore Volume (cm3/g) = Volume of water added (cm3) / Sample Weight (g)
Test Method 16 Total water added/kg API - granulation point This is the amount of water added to a dry mixture of 80wt% mixed metal compound and 20wt% excipients in order to form granulates (i e until a granulation point is reached)
Test Method 17 Tablet Volume The tablet volume is calculated from the dimensions of the tablet using a computer design package (iHolland Ltd).
Test Method 18 Rate of drying For the calculation of rate of drying (kg water/(kg dried product.hr)) mass of water removed during drying per unit time was divided by the mass of dry product produced. The time used to calculate the rate of drying is the dryer residence time defined in Test Method 19. Test Method 19 Dryer Residence Time
For long residence dryers, the residence time is the time during which water is removed from the material being dried. For short residence dryers such as spray drying, the residence time is calculated as follows
The internal volume of the dryer is first determined The residence time of the air or gas fed to the dryer is then calculated by dividing the interval volume by the air or gas flow rate It is assumed, since a significant build up of solids does not occur within the dryer, that the average particle residence time is approximately equal to the air or gas residence time
Test Method 20 Product rate per unit area
The Product rate per unit area kg product/(m2 hr) can be calculated by dividing the mass of dry product produced per unit time with the surface area used for heating
Test Method 21 Deita T
Delta temperature is defined for short residence drying processes as (T,n - Tout )/ Tm where
Tm is inlet gas temperature, 0C
T0Ut ts the outlet gas temperature or product temperature, 0C (assuming gas and product are at the same temperature)
Test Method 22 Tapped Bulk Density Tapped Bulk Density was determined using a Copley JV1000 Auto tapper The measurement was made by the addition of the product (50.Og, +/- 5 Og) into a clean measuring cylinder (dedicated for the apparatus) The exact weight was noted The initial volume was noted The cylinder was then placed on the auto tapper and the machine was set for 3750 taps by entering the number of taps required and then pressing start The volume of the cylinder was taken again when the total number of taps was completed (end volume) The tapped bulk density was calculated as follows,
Tapped Bulk Density (g/rπi) = weight (g) / end volume (ml)
Test Method 23 Flowabjlity Carr Index
The Carr index was calculated using the following formula and the data available from the Tapped Bulk Density test,
Carr Index (%) = 100 * ((initial volume (ml) - end volume (ml)) / initial volume (ml))
A result greater than 25% indicates poor flow ability and less than 15% indicates good flow ability Test Method 24 Ayerage.Particle Size Distribution (d50 PSD) of powders
The particle size was determined using a Mastersizer 'S' fitted with a 300Rf iens and a DIF 2012 dispersion unit The data was interpreted and analysed using Malvern Mastersizer software. The Malvern was connected to process water supply. The following program parameters were used, 80% pump speed, 80% stirrer speed, 50% ultrasonic and 3 minute residence time The background level was checked to be beiow 100 units When prompted by the program the sample was added in portions to reach between 15%-25% obscuration The analysis commenced automatically. The residual was checked to be less than 1 %. The sample was analysed in duplicate The results were calculated using the software by taking the % volume under the particle sizes between 1 .85 and 184 microns This was expressed as percentile results with the Average Particle Size {D50, 5O5h percentile), 90th Percentile (D90) and 10th Percentile (D10)
Test Method 25 Metal Analysis of Al, Cr, Pb
Samples were acidified, diluted and the specified metals analysed using ICP-MS, Samples were analysed in duplicate
Test Method 26 Total Heavy Metal Content
The metals were determined by acidifying the samples first followed by analysis using ICP-MS Total heavy metal content (ppm) was then calculated by summating the following metals; As (ppm) + Cd (ppm) + Pb (ppm) + Hg (ppm) + Sb (ppm) + Mo (ppm) + Cu (ppm)
Test Method 27 - Power per Unit Volume Computational Fluid Dynamics (CFD) software application was used to simulate fluid flow within the reaction vessel to establish mixing requirements in mixing equipment.
RESULTS AND DISCUSSION
We have encountered critical problems with the larger scale process of manufacture (defined as being from the reaction to drying stages) when trying to prevent increase in crystallite size This is described in more detail below PHOSPHATE BINDING
For, high daily and repeated long-term (chronic) dosages required for kidney patients total daily pill count requires a low tablet burden due to restricted fluid intake Consequentiy, high dosage of drug substance (mixed metal compound) of up to 80 wt% is required in final product (i e tablet) whilst maintaining good therapeutic activity (such as phosphate binding) and storage stability We have found that the final product is therefore very sensitive to an array of opposing chemical and physical properties of the mixed metal compound such as composition (Mg Fe ratio, sulphate) , crystallite size, morphological properties (surface area, particle size, pore volume) of the mixed metal compounds This is unlike normal requirements imposed on pharmaceuticals which typically contain more soluble, organic type drug substances at iower concentrations which are less dependent on a particular morphology
Variants of the Mg:Fe hydrotaicite structure that had different Mg Fe molar ratios of 2:1 , 3'1 and 4 1 were compared for phosphate binding performance and magnesium release (Table 2) The release of the magnesium, associated with the pharmaceutical use of mixed metal compounds can be reduced by selecting a suitable Mg:Fe molar ratio Data showed that material with a ratio of 2 1 had the highest phosphate binding per mole of magnesium released in a phosphate binding test in the presence of a meal slurry The data also shows that a Mg Fe molar ratio of 2:1 does not have the presence of any other non-hydrotalcite phases In addition, we have found that unaged mixed metal compounds of crystallite size less than 200 angstrom (A) give higher phosphate binding than those of aged compounds which typically have a crystallite size well above 200 A.
Figure imgf000081_0001
However, we have found that if processed incorrectly the mixed metal compounds crystallite size will continue to grow in size and are difficult to filter, particularly at large scale this presents significant problems. We have discovered a novel process for control of different production steps (from reaction to drying) such as to prevent growth of the crystallite size above 200 A in order to maintain the phosphate binding activity without significantly hindering the process of isolation, washing and drying of the compound. This was achieved by careful selection and control of specific process conditions. Our approach is described in more detail by the following examples PRECIPITATION
We have found that the advantages of the mixed metal compound of Mg. Fe molar ratio of approx 2.1 such as good phosphate binding are not only determined by crystallite size but also preferably by low levels of iπteriayer sulphate and the method of manufacture (Table 3 and Figure 1) Furthermore, across the pH range considered, filtration is difficult due to the typical clay-like structure of the material.
When preparing the mixed metal compound with the carbonate anion the presence of a second anion-type may be possible. The presence of only one anion-type may be considered more desirable than a mixture of anions Surprisingly, we discovered that it is not necessarily optimal to have no sulphate but that a small amount of sulphate should exist as interlayer (bound) sulphate in order to increase filtration rates of the clay-like structure whereas the sulphate in the form of soluble salts such as Na2SO4 should be removed. We found that most of the soluble Na2SO4 salt can be readily removed by washing whereas the interlayer sulphate is less soluble and its levels are primarily controlled by the amount of excess Na2CO3 in the recipe, reaction pH and extent of ageing in the reaction slurry (Le, temperature of reaction slurry) For example, we have found that the interlayer sulphate decreases when: reaction temperature of slurry increases, the excess Na2CO3 increases, the pH increases.
Optionally, if the interlayer sulphate needs to be reduced further to achieve an even higher purity (i e less than 1 0 wt% interlayer sulphate ) and initial isolation and washing rates are not to be reduced it may be possible to wash the filter cake again but this time with a solution of Na2CO3 (preferably up to 1 M concentration) followed by washing with water. This process may reduce or remove the remaining interlayer sulphate without necessarily reducing filtration rates or phosphate binding However, it is preferred if most of the inter layer sulphate is removed during the reaction stage instead of requiring the need for washing with carbonate Additionai process steps may decrease yield as we)! as encouraging crystallite size growth Therefore in another aspect of the invention the compound is first washed with water to remove soluble SO4 and sodium, followed by a wash with a Na2CO3 solution to remove the interlayer sulphate, followed by a final wash with water to remove any remaining soluble ions Preferably the compound is slurried with some Na2CO3 solution for up to 1 hour to enable exchange of the interlayer sulphate for the carbonate It is believed that washing with excess Na2CO3 would encourage removal of any remaining sulphate from the interlayer region In this aspect after the exchange of the interlayer sulphate for the carbonate there may be provided an AI-free mixed metal compound with less than 1 wt% interlayer sulphate (preferably less than O 5 wt%) and less than O 5 wt% soluble sulphate.
Where product is not washed with Na2CO3 solution we have also found that phosphate binding varies as a function of sulphate level, for example, an optimum interlayer sulphate level exists of between 1.8 to 5 %wt, wherein good phosphate binding and filtration is maintained Phosphate binding decreases below 1 8 %wt Above 5 %wt interlayer SO4 becomes more variable and the SO4 level is too high to be acceptable and wash and filtration time increases. Best results were obtained between 2 5 and 5 wt% interlayer sulphate.
Table 3 Effect and control of interiayer sulphate on wash time and phosphate binding
Figure imgf000084_0001
Area highlighted is preferred range
SEPARATION
The features of the Al-free mixed metal compounds resulting from their clay-like structure, replacing Al with Fe and their unaged form present limitations when manufactured on a commercial scale Limitations such as difficult filtration and material hardness have to be resolved whilst at the same time maintaining a process at scale and a mixed metal compounds with good phosphate binding, storage stability and not negatively affecting the downstream manufacturing processes used to produce the final formulated pharmaceutical product containing the mixed metal compound
During scale-up we found that it was difficult to prepare this material when using traditional filtration techniques such as a belt filter, Neutsche pressure filter Even a centrifugation method did not work effectively at this large scale. We solved this problem by selecting specific ranges from one or more of the following (i) selection of range of interlayer sulphate (from 1 8 to 5 wt%) by control of Na2CO3 and pH (ii) selection of a preferred psd of reaction slurry (D50 > 40 microns, preferably greater than 70 microns) and moisture content of reaction slurry (more than 90 wt%) and filter cake (less than 80 wt%) (iii) selection of a specific agitation regime (a power per unit volume of 0 03 to 1 6 kW/m3), (iv) selection of a preferred filtration method and its operation (centrifuge) In a highly preferred aspect we selected each of the following: (i) selection of range of interlayer sulphate (from 2 to 5 wt%) by control of Na^CC^ and pH (ii) selection of a preferred psd of reaction slurry (D50 > 40 microns, preferably greater than 70 microns) and moisture content of reaction slurry (more than 90 wt%) and filter cake (less than 80 wt%) (iii) selection of a specific agitation regime (a power per unit volume of 0 03 to 1 6 kW/m3), (iv) selection of a preferred filtration method (centrifuge)
(i) Interlayer Sulphate A high filtration rate and a low wash time are advantageous when seeking to manufacture the MgFe mixed metal compounds on a commercial scale and to prevent crystallite growth However, mixed metal compounds consisting of low interiayer sulphate levels (less than 1 8 wt%) are more difficult to filter and wash whereas if too high in sulphate (above 5 wt%) then washtime increases again (Table 3 and Figure 1) We found that interlayer sulphate levels can be maintained between 2-5 wt% by controlling the temperature of the reaction slurry, pH during the reaction and a Na2CO3 (XS) excess range of either one of the following combinations shown below
When the slurry is maintained to a temperature between 15 and 30 DC wherein the NaaCθ3 is provided at an excess than is required to complete the reaction and a pH at either:
(i) 9 5 < pH≤ 1 1 and O < Na2CO3≤ 1 moles
(ii) 9 5 < pH < 10 5 and 1 < Na2CO3 < 2 moles
(iii) 9 5 < pH < 10 1 and 1 < Na2CO3 < 2.7 moles
(iv) 9,5 < pH < 10 and 1 < Na2CO3 S 4 moles
(V) 9.5≤ pH < 9.8 and 1 < Na2CO3 ≤ 5 moles
When the slurry is maintained to a temperature from 30 to 60 0C wherein the Na2CO3 is provided at an excess than is required to complete the reaction and a pH at either:
(i) 9 5 < pH < 1 1 and O < Na2CO3< 2
(ii) 9 5 < pH < 10 5 and O < Na2CO3 < 2.7 moles
(iii) 9 5 < pH < 10 and O < Na2CO3 < 4 moles
Excess Na2CO3 (XS) is defined as excess than is required to complete the reaction of. 4MgSO4 + Fe2(SO4J3 + 12 NaOH + (XS-M JNa2CO3 -> Mg4Fe2(OH)12. CO3.nH2O + 7Na2SO4 + (XS)Na2CO3
For mixed metal compounds, maintaining the target metal molar ratio (Mg:Fe) at approx 2 (1 ,8 to 2.2, preferably 1 7 to 2 1) during the reaction whilst controlling the interlayer sulphate is difficult as both are opposingly affected by the way the material is processed. Furthermore, we found that correct stoichiometry is not only determined by the correct ratios of the starting materials but also by pH for the reaction For example, when the pH is too low (pH below 9 5) incomplete precipitation of magnesium may occur whereby Mg: Fe molar ratio fails well below the target value of 2 and is also not free of non- hydrotalcite crystalline phases. It is therefore preferred to maintain the pH between 9 5 and 1 1 and preferably between an even narrower pH range of 9 5-10 and more preferably at 9.8 to deliver the optimum magnesium, iron ratio (1.8 to 2.2, preferably 1 7 to 2.1 ) whilst maintaining good filtration rates during manufacture at scale, maintain good phosphate binding and prevent crystal growth by control of particle size distribution and interlayer sulphate. The total amount of anion (Ccaic) predicted for a mixed metal compound if it were of an ideal hydrotalcite type phase of a M2+1M3+ molar ratio of 2:1 can be calculated by the foliowing formula: Ccaic = (Wt3V (M2+ + M3+))/n wherein n is the charge of the anion. For example, a M2+:M3* molar ratio of 2-1 and an assumed anion charge n = 2 (i.e. as for CO3 2" or SO4 2") would result in a predicted value for (Ccaic) of 0, 17. The experimental value for Cexp can be determined from the sum of the amount (mole equivalent) of sulphate and carbonate anion The Δ is defined as the difference between the C calculated and C experimental wherein a lower Δ value indicates a more pure hydrotalcite phase The smallest Δ value is observed when precipitating above pH 9.5.
The data of Table 3 (shown in Figure 1 ) and the description of examples 8-24 in the example section shows that the best overall quality (i.e. good phosphate binding, high filtration rates, low wash times, a molar ratio of approximately 2 0, no non-hydrotaicite crystalline phases and a small Δ) are obtained for those samples wherein the interlayer sulphate levels are between 2 and 5 wt%, and preferably a sulphate to carbonate molar ratio of between 0.14 to 0.26. The total amount of anion (sulphate and carbonate) is preferably from 0,15 to 0.20 more preferably is of 0.19 mole equivalent,
In order to control interlayer sulphate below 3%, the Na2CO3 had to be of more than 2 mole excess To maintain the interlayer sulphate above 2 wt% the precipitation pH has to be less than 10 and of 2.7 moles excess Na2CO3 or less
Sodium carbonate not only provides the carbonate for the anion-exchange sites, but also acts as a pH buffer which assists pH control during precipitation. The ability to maintain an accurate precipitation pH is considerably increased when NaaCO3 is present and for that reason an excess of Na2CO3 of more than 2 is preferred. However, we found that an excess Na2CO3 of 4 or above is less preferred because this could result in an increased risk of incomplete dissolution of Na2CO3 in the reactaπt solution at the preferred reaction temperatures (of less than 250C) when preparing unaged mixed metal compounds.
For example, during dissolution of the sodium hydroxide and sodium carbonate in the feed-solutions, the solution temperature may rise to 65 0C and we found that an excess in Na2CO3 of 4 or more does dissolve; however, cooling and/or pressurisation was required during dissolution to limit evaporation and to lower the temperature to the same value as that required for the reaction to prevent ageing When the Na2CO3 solution (of more than 4 moSe excess) is cooled from 65 to 25 0C partial precipitation of the Na2CO3 occurs
It was therefore preferred to maintain the Na2CO3 at 4 mole excess or less We found that it was possible to lower the excess NaaCOs from 4 to 2.7 mole without affecting pH control
To summarise, the data of Table 3 suggest that when outside a range of 1.8 to 5 wt% interlayer sulphate, phosphate binding either decreases and/or the Mg. Fe molar ratio of 2 O is not maintained and/or separation of the slurry is more difficult to achieve A Mg. Fe molar ratio of 2 O was targeted such as to obtain the highest phosphate binding per mole of magnesium released A preferred range of between 1 8 to 5 wt% interlayer sulphate was achieved by selection of pH and Na2CO3 excess within a narrow range. (ii) Reaction slurry psd and filter cake moisture content
Particle Size Distribution (PSD) - The particle size distribution is an important material parameter which influences the filtration time of the reaction precipitate slurry, In the laboratory with similar reactant concentration, reactant addition rate, reaction temperature and pH and water heel volume, differing agitation configurations produced different PSDs Thus the PSD of the reaction precipitate is strongiy influenced by the agitation regime, the vessel configuration, and the mode of reactant addition. We have identified the agitation conditions at commercial scale to enable optimum filtration and washing conditions whilst ensuring that the final product is essentially unchanged from that at low tonnes per annum scale.
Without being bound by theory it is postulated that high pH / sub-optimal mixing can result in a small particle size which can block up the filter cloth, reduce the filtration rate through the cake and limit the ultimate solids content of the filter cake We found that there is a significant increase in filtration time when reaction slurry psd (d50) is reduced to less than 70 microns Investigations (data shown in Table 4) demonstrated that control of particle size above approximately 70 microns is preferable in maintaining a high filtration rate suitable for use of separation methods on a commercial scale such as centrifuge, Neutsch and belt filters. In addition, we found that unwanted crystal growth (ageing) can be minimised if filtration time is kept at a minimum We also found that a reduction in particle size to less than 70 microns leads to an increase in moisture content of the filter cake to more than 80 wt% This filter cake is stickier and is therefore more difficult to remove from the filtration equipment and will tend to hold up in mechanical devices or containers during handling A preferred moisture content of the filter cake is therefore iess than 80 wt% Consequently, separating the mixed metal compound from reaction slurry of more than 90 wt% moisture content is also preferred
There is therefore a preferred combination of both a filter cake of moisture content (iess than 80 wt%) and a PSD (of more than 70 microns) to enable manufacture on a larger scale of compositions free of aluminium
(iii) Agitation regime
The results described herein demonstrate that the preferred PSD of reaction slurry are obtainable when maintaining the reaction pH between pH 9 5-1 1 (preferably at pH 9 5 to 10, more preferably 9 8) In general, the teachings of WO99/15189 would not enable separation of the compound on a commercial scale Furthermore, we found that the method of agitation (power per unit volume of 0,03 to 1 ,6 kW/m3 ) during precipitation is preferred Slow stirring (i.e sufficient to maintain the solution homogeneous) was then maintained during the hold time We found that filtration time increased significantly when the slurry is stirred for a prolonged period during the hold time For example, we found that a hold time of more than 30 minutes but less than 12 hours is preferred and the slurry during hold time should be agitated gently. The slurry hold time is defined as the time period between when the addition of Solutions A and B ceases (reaction phase ends) and the last aliquot of slurry is added to the filtration equipment At pilot plant and large commercial scale where centrifuges are used, the slurry hold time is typically up to 12 hours since multiple aliquots of reaction mass are isolated, washed, dewatered and discharged as wet cake
The specific reaction agitation configuration to maintain low shear conditions whilst at the same time enabling sufficient mixing were also found to be useful in obtaining a preferred psd of more than 70 microns (when measured at the end of hold time). The specific power input has to be controlled such as to avoid a rate which is too low but not at a rate which breaks the particles down into very fine particles of psd less than 70 microns
Evaporation of water from the reaction slurry and ageing of crystallites was prevented by maintaining the reaction temperature below 30 Celsius and typically was not less than 15
Celsius to avoid unacceptable reduction in reactant feed stream solubility Table 4 Effect of slurry Particle Size Distribution (PSD) on filterability
Figure imgf000090_0001
Figure imgf000091_0001
(iv) Selection of a preferred filtration method and its operation
In general, a filtration method is used to isolate the product from slurry form, wash to a predetermined impurity end point and de-water the cake in order to obtain a material of sufficiently high solids content to facilitate handling and for efficient drying. In the case of laboratory filtration equipment de-watering is typically not carried out due to the limitations of the equipment used and due to small quantities handled Tangential Flow Filtration (TFF)
A method whereby filtration rate increases when psd is less than 70 microns is the Tangential Flow Filtration (diafiltration) method (Table 4 and 5); however, diafiltration in general has significantly lower filtration rates (at all psd ranges) and is only suitable for filtration of diluted slurries of more than 94 wt% moisture content Reaction slurry could be washed, but not concentrated, since moisture contents below approximately 94 wt%, would lead to blockage of the TFF The washed slurry would then require much greater energy input during drying Consequently, separation by diafiltration is less preferred Neutsche Filter
Isolation and washing of the drug substance was also carried out using a Neutsche filter at a 7 kg production scale This equipment gave good product separation and washing but the specific filtration rate (kg product / m2 h) was extremely slow and the filter cake contained up to 85 wt% moisture content requiring much increased energy usage during drying A cake depth of ~ 7crn was achieved in the Neutsche filter and 10cm in a filter/ drier, whereas cake depths of 30cm or more are not uncommon for ftiter/driers in other applications, Separation, by Neutsch filter we found to be iess preferred for manufacture on a commercial scale because of Sower filtration rate and limitations in handling larger amounts of the clay-like product.
Belt Filter
A belt filter is preferred as we found that these could be operated with a cake depth range of 15-25 mm at relatively high filtration rates This filtration method provides high filtration rates when psd is maintained above 70 microns
Centrifuge
Different filtration methods were tested but best results were obtained with a filtration method using centrifuge which combines filtration followed by washing and de-watering in one step. Centrifugal filtration is preferred and provides advantages of high filtration rate and preferred filter cake moisture content whilst maintaining the quality of the product (Table 4 and 5)
Table 5 Selection of filtration methods
Figure imgf000092_0001
DRYING
We found that too much processing and handling; for example, such as overdrying can present changes (such as growth of crystallite size) that are unacceptable in the final mixed metal Mg Fe compound How the API morphology (vi) affects storage stability and downstream processing is shown in Table 6 How to control drying to achieve the required porosity (vii) and crystallite size (viii) is described in more detail in Table 7 and 8 (vi) Morphology
High daily, repeated long-term (chronic) dosages and restricted fluid intake are required for kidney patients Consequently, a high dosage of drug substance is required in the final product (i e tablet) and the manufacture and qualities of the final product is therefore sensitive to the form and shape (morphoiogy) properties of the mixed metal compounds drug substance, unlike more typical formulations. This means that the properties of the tablet, including key physical properties, and the tablet manufacturing processes, such as granulation, are often primarily influenced by the properties of the mixed metal compound active substance rather than those of the excipients, as is more typically the case. In order to be able to manufacture a pharmaceutical product comprising such significant quantities of mixed metal compound with the control and consistency necessary for pharmaceutical use, a means of controlling an array of these physical properties of the mixed metal compounds is essential It is important to dry the material carefully as it is easy to change the surface area or internal pore volume and hence change the therapeutic activity (Table 6).
Table 6 Effect of API morphology on granules and tablets properties..
Figure imgf000094_0001
Table 6 shows how pore volume and surface area affects the control of phosphate binding capacity, storage stability, the granulation process and the production of tablets. As a general rule, hydrotaicite type materials of a higher surface area may be expected to have a higher ion exchange capacity and thereby higher phosphate binding; this can be seen from Example 66 which has a high surface area of 1 19 m2/g and also a high phosphate binding value- However, the materia! with the higher surface area of 119 m2/g was found to be less stable upon storage because phosphate binding activity decreased by 12%, We have found that a lower surface area range of between 40 and 80 m2/g is more preferred as it has the advantage of maintaining good phosphate binding (more than 0.6 mmol/g API) that is importantly also essentially unchanged (only 5% or less change) upon storage over periods of up to years, making it more viable as a an active pharmaceutical materia!.. It may be expected typically that significantly higher surface areas would be required to attain such stable phosphate binding - such materials of lower surface areas (by N2) of between 40-80 mz/g and have a pore volume (by N2) of 0.10-0.28 cm3/g and/or a pore volume (by water) of 0 3-0.6 cm3/g may be expected to have greater sensitivity to any changes in the internal structure resulting in the inhibition of access of the phosphate ions into the material and consequential reduction in phosphate binding capacity Surprisingly, the data presented in Table 6 shows that all these examples of mixed metal compound of lower surface areas are storage stable and maintain good phosphate binding Furthermore, the materials of lower surface areas, in the range of between 40-70 m2/g and low pore volume (water) of 0 3-0 6 crn3/g offers the advantage of a denser materia! that can then be processed into a dosage form that is smaller (re as can be seen from Table 6 tablet volume of less than 500 mm3) thereby improving tablet pilt burden; a prevalent issue within the treatment of renal patients Furthermore an additional surprising benefit is that such materials also exhibit no significant reduction in the uptake rate of phosphate, despite the lower surface areas This facet can be important when considering such materials for pharmaceutical applications in which the binding of phosphate needs to be rapid, such as renal care. We have also found that the material of crystallite size less 200 A binds greater than 80% of phosphate within 10 minutes (according to Test method 3 but measured at different time intervals) when maintained at a average particle size less than 100 μm, preferably less than 50 μm, most preferred less than 10 μm and a surface area more than 40 m2/g. (vϋ) Manufacture of unaged, porous mixed metal compounds (drying)
We have found that the surface area of the drug substance is determined by a combination of rate of drying, residence time, product rate per unit area and delta T (Table 7). The rate of drying is affected by both the mode of drying and other process parameters, such as the product temperature, heating surface/ gas temperature
A product of crystallite size between 90 and 200 A and a surface area (by N2) of between 40-80 m2/g, and/or pore volume (by N2) of between 0 10-0 28 cm3/g, and/or pore volume (by water) of between 0 3-0 6 cm3/g can be achieved by exposing the crude product to a product temperature of more than 80 but no greater than 15O0C and provide a rate of drying (water evaporation rate) of between 0 05 to 0.5 kg water per hour per kg of dry product and/or provide a dryer residence time of between 10 minutes to 30 hours and/or a product rate per unit area of between 0-7 kg product / (m2 hr) typically achieved by use of a high residence time dryer under a vacuum of pressure of 400 mbar (absolute) or less. A product of low pore volume (by water) range of 0 3-0 6 cm3/g can be obtained by a combination of the centrifuge and use of agitated spherical dryer method.
Alternatively, a product of crystallite size less than 140 A and a surface area (by N2) of between 80-150 m2/g, and/or pore volume (by N2) of between 0 28-1 0 cm3/g, and/or pore volume (by water) of between 0 6-1 2 cm3/g can be achieved by exposing the crude product to a product temperature of more than 350C but no greater than 15O0C and provide a rate of drying (water evaporation rate) of between 500 to 50000 kg water per hour per kg of dry product and/or provide a dryer residence time of less than 10 minutes and/or a delta T of between 0 2 to 1 0 typically achieved by use of a short residence time dryer
Table 7 Effect of rate of drying on morphology
Figure imgf000097_0001
(vϋi) Effect of rate of drying on crystallite size
Table 8 shows that the drying must be sufficiently rapid so as minimise crystal growth, however bulk product temperatures exceeding 150°C must be avoided in order to prevent damage to the characteristic material structure. Factors such as agitation during drying in long residence time dryers were also found to effect crystallite size. For example, dried samples (such as obtained by Neutsche / Tray Oven) whereby no continuous agitation is applied tend to show smaller crystallite size than those obtained by a spherical drier. Therefore an optimum drying regime exists
Table 8 Effect of drying conditions on control of crystallite size
Figure imgf000098_0001
Figure imgf000099_0001
For those compounds wherein the average crystal size of the mixed metal compound is from 10 to 2ϋnm (100 to 200 A) preferably from 12 to 20 nm, the surface area (by N2) is between 40-80 m2/g, pore volume (by N2) is between 0 10-0 28 crrvVg and the pore volume (water) is from 0 3-0 6 cm3/g The compounds of average crystal size between
100 to 200 A are preferably obtained by use of a long residence agitated drying process such as an agitated spherical dryer wherein the rate of drying is between 0,09 to 0 31 kg water/(kg dried product hr), more preferably a rate of drying between 0.24 to 0 31 kg water/(kg dried product hr) and/or a Product rate per unit area (kg product/m2 hr) of between 1-10 more preferably between 2-7
We have found, surprisingly that the advantages of the lower surface area product of crystallite size between 100 and 200 A and/or low surface area 40-80 m2/g and/or low pore volume (water) 0,3-0.6 crn3/g prepared by a long residence drying process are good phosphate binding, storage stability and a denser material that can be processed into a dosage form that is smaller thereby improving tablet pill burden Average crystal size of less than 200 A has the advantage of good, controlled phosphate binding A average crystal size of between 120-200 A is preferred if product is dried to a moisture content less than 15 wt% (preferably between 5-10 wt%) of a batch size of between 50 and 1000 kg when dried by a process of long residence drying with a agitated spherical dryer and when preparing materials of a low surface area of between 40 and 80 m2 per gram and/or pore volume (water) of 0.3-0 6 cm3/g. The low porosity product is preferably prepared from batch sizes between 50 and 1000 kg with a dryer residence time of between 3-30 hours, more preferably between 5 to 30 hours and most preferred between 9 to 30 hours MILLING
Optionally, after the drying step the dry material may be first classified to remove oversize particles by milling and/or sieving (ix) Effects of PSD on phosphate binding and magnesium release
We have found that Mg release remains constant whereas phosphate binding changes as a function of particle size (Table 9) This is a surprising result as a smaller particle size distribution could be expected to have a larger surface area and therefore more susceptible to Mg release However, the magnesium release does not appear to be significantly affected by changes in surface area when maintained at less than 80 m2/g despite being milled to a particle size distribution (psd) with a (d50) of less than 60 micron when using this route. The constant Mg release enables a wider selection of a preferred psd range to improve phosphate binding without compromising Mg release. The data from Table 9 shows that a preferred particle size d50 is less than 177 micron, more preferably less than 114, most preferred less than 60 micron
Table 9 Effect of particle size distribution of dried product on phosphate binding and magnesium release
(x) Effect of crystallite size on milling rate
Figure imgf000100_0001
If processed incorrectly mixed rnetal compounds can become unacceptabiy hard This can lead to consequent issues of decreased milling rates and higher energy input to achieve a preferred particle size The consequence of this is that in achieving a given particle size it is essential that the crystallite size is not too low
Table 10 shows that if the crystallite size is too Sow (i e. of 120 A or less) the milling rate will be reduced by more than 50% when compared to that of crystallite size of 195 A which will present difficulties at scale when milling to a particle size distribution with a d50 of !ess than 1 14 micron For example, problems with occurrence of non-hydrotalcite phases such as MgO periciase, reduced milling rate or decomposition of the product because of over-heating of the product can occur For those mixed metal compounds wherein the crystallite size is less than 120 A it is preferred to use the short residence drying route which does not require milling Table 10 Effect of crystallite size on milling rate and phosphate binding
Figure imgf000101_0001
If the reaction pH rises above pH 11 (and to a certain extent above pH 10) we have found that the resultant mixed metal compounds is a much harder material. It is therefore possible to prepare a softer material by precipitation at pH 9 8 than at higher pH values Consequently, not only does precipitating at a pH of 9 8 provide the advantage of increased filterability we have also shown this to be of benefit for achieving increased milling rates
Control of material hardness is also important because this may also increase the potential for pickup of low levels of trace-metals from the milling equipment When the material is harder it also has to be milled harder which in turn can lead to higher temperatures being generated during milling which provide a milled material which can contain decomposition products or may be too dry (iess than 5 wt% moisture content as determined by LOD) which in turn can lead to problems with handling and the downstream processing (xi) Methods of micronisation if the moisture content of the unmilled product is above 10 wt% then the product can become too sticky for milling whereas if less than 5 wt% the product after milling will be too dry and would then be less stable upon storage and/or provide problems in processing into tablet formulations. We found that the milling process results in a further 2 wt% loss of moisture resulting in a milled product We therefore typically target a moisture content of between 7 and 10 wt% for the unmilled material
The chemical (i.e. molar ratio of Mg. Fe of 2.1) and physical properties (i e surface area and particle size) of the mixed metal compounds composition favour equilibration to a 5- 8 wt% moisture content and as such may be less stable upon storage (i.e have a tendency to re-hydrate) if manufactured to a moisture content less than 5 wt%,
We have found that this compound can be manufactured using a process comprising a short residence drying step such that the resultant representative material has both small average crystal size and high surface area but also importantly and surprisingly exhibits high phosphate binding even when the materia! is not milled further The requirement for no milling has the advantage of reduced processing steps. A further advantage is that such material can be suitable for tabletting processes without the need for wet granulation due to the advantageous flow properties. Therefore, in one aspect the present invention provides a mixed metal compound wherein the average crystal size of the mixed metal compound is less than 20nm (200A); in this aspect preferably the surface area is from 80 to 145 m2 per gram. The data from Table 1 1 shows that for a mixed metal compound with a surface area from 80 to 145 m2 per gram the preferred particle size d50 is less than 343 micron, more preferably less than 296, even more preferably less than 203, most preferred less than 31 micron. Table 11
Figure imgf000103_0001
The compound of higher surface area of 80-145 m2 can be manufactured using a process comprising a short residence drying step such that the resultant representative material has both small average crystal size and high surface area but also importantly and surprisingly exhibits high phosphate binding even when the material is not milled further. The requirement for no muling has the advantage of reduced processing steps and avoids any hardness issues A further advantage is that such material can be suitable for tabletting processes without the need for wet granulation
IMPURITY
Mixed metal compounds may be synthesised by various techniques; however, it is difficult to control impurity levels of compounds when isolated in the unaged form, to a pharmaceutical grade and when prepared Al-free especially when considering that mixed metal compounds are prepared from minerals containing significant levels of trace-metal impurities some of which may be in the form of heavy metals. In particular, compounds prepared from iron minerals are considerably intermeshed with other metal types as these ultimately are derived from minerals that exist in nature. Some of these metals may compete with the magnesium and iron for formation of the mixed metal compound and get locked into the hydrotalcite phase instead of forming more soluble salts which are readily washed out during the washing process. There is therefore a need to control trace metal impurity levels by selecting preferred conditions and recipe during the precipitation stage; this in order to meet regulatory guidelines whilst obtained via a manufacturing process that can deliver this at scale. Other impurities, such as sodium and sulphate must be controlled in order that the drug substance is of acceptable quality for human consumption The sodium concentration is controlled through washing of the isolated drug substance cake,
During the filtration and washing step of the manufacturing process, the slurry is formed into a cake (with the removal of excess mother iiquor). The resultant cake is then washed with water to remove excess sodium, sulphate and carbonate down to levels acceptable for the final use of the material
For pharmaceutical use it is important to be able to identify and control the crystal phase of interest. The way the material is processed influences this, when preparing a compound from 2 different meta! types it is possible that it may precipitate as a mixture of single metal compounds instead of a mixed metal compound Mixed metal compounds are manufactured by co-precipitation which can encourage the formation of different crystalline phases in addition to the hydrotalcite phase There is therefore the need for a Al-free mixed metal compounds which are also free of any other crystalline phases as determined by the absence of XRD diffraction lines except those attributed to the hydrotaictte phase When prepared according to the process defined for the unaged samples of crystallite size less than 200 A we have found that the hydrotalcite phase has the following diffraction X-ray diffraction analysis without the presence of any other crystalline phases: dA ('d! spacings) 7 74, 3 86, 2 62, 2.33, 197, 1.55, 152, 1 44. Five additional peaks at dA 3.20, 1 76, 164, 148, 1 40 are only resolved in more crystalline samples Le of crystallite size above 200 A1 typically as a result of ageing
Trace meta! impurities must be controlled in order that the drug substance is of acceptable quality for human consumption. We found surprisingly that trace metal concentrations can be controlled by the reaction pH, reaction hold time (ageing) and not only as would be expected by the selection of raw materials of appropriate quality or washing. For example, Table 12 shows how we have been able to further reduce the aluminium (Al) and lead (Pb) levels by control of pH, control of sodium carbonate excess and control of ageing. Table 12 Effect of recipe, reaction conditions on trace metals content mixed metal compound
Figure imgf000105_0001
From Table 12 it is possible to conclude that even when changing from a solution (A) of GPR grade Rectapur to a more pure ferric source (B) such as a solution (40.4 to 42 9 wt% ferric sulphate of water industry standard suitable for human consumption conforms to BS EN 890:2004), the aluminium levels may be decreased further (i.e. to less than 30 ppm) by avoiding excessive ageing (i.e. wherein the crystallite size is > 200 A) Example 62 was prepared with solid aluminium sulphate of Alfa Aesar 98% CAS 17927- 65-0 instead of ferric sulphate. All other raw materials were of the same source.
All samples shown in Table 12 were washed equally as indicated by low (<0.5 wt%) and similar Na2O levels. The washing process was developed such as to provide the required Na2O levels.
As discussed herein the aluminium levels of the mixed metal compound are less than
10000 ppm. This level is considered suitable AI exposure for a healthy individual and is typical of pharmaceutical grade compounds (t e. of 99% purity) In contrast, mixed metal compounds commercially available as antacids in the form of a Mg AI mole ratio of 3:1, typically contain ten times as much AI (i e up to 100000 ppm aluminium) and are therefore not suitable for long term use. Renal patients are prone to aluminium accumulation it is therefore more preferred if the aluminium content is less than 2000 ppm (>99 8% purity) based on a total daily intake of 6 g/day and general regulatory guidance
We have found that a Al level of 1000 ppm (99,9% purity) is achievable when using a large scale process for manufacture of unaged materials. For renal patients an aluminium content as low as possible is preferred and therefore a aluminium content of less than 1000 ppm is more preferable Using our process we can typically achieve aluminum levels less than 100 ppm; therefore aluminium levels less than 100 ppm are even more preferred By careful control of reaction conditions we can achieve aluminium levels less than 30 ppm which is most preferred, The data of Table 12 also demonstrates that it is possible to maintain lead (Pb) levels below the detection limit of < 1 ppm when precipitated at pH 9 8 and using an excess of 2,7 moles Na2CO3 in the recipe instead of precipitating the mixed metal compound at pH 10 5 and using an excess of 4 0 moles Na2CO3 even when using a more impure source of ferric sulphate. We also found that the total heavy metal content couid be maintained at less than 10 ppm total heavy metals (Test Method 26) when using the preferred recipe of pH 9 8 and an excess of 2.7 moles Na2CO3
Chromium (Cr) levels are required to be limited to <25 ppm according to the guideline of metal reagents for medicinal compounds CHMP/CWP/QWP/4446/00 Table 12 demonstrates that we have been able to lower the chromium levels from approximately 35 ppm to below the detection limit (less than 1 ppm),
Al! publications and patents and patent applications mentioned in the above specification are herein incorporated by reference. Various modifications and variations of the present invention will be apparent to those skilled in the art without departing from the scope and spirit of the invention. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various
modifications of the described modes for carrying out the invention which are obvious to those skilled in chemistry, biology or related fields are intended to be within the scope of the following claims

Claims

1 A method of producing a mixed rnetal compound comprising
at least Mg2+ and at least Fe3+
having an aluminium content of less than 10000 ppm,
having an average crystal size of less than 20nm (200A)
comprising the steps of
(a) combining a Mg2+ salt and a Fe3+ salt with Na2CO3 and NaOH to produce a slurry, wherein the pH of the slurry is maintained at from 9 5 to 11, and wherein the Na2CO3 is provided at an excess of 0 to 4 0 moles than is required to complete the reaction
(b) subjecting the slurry to mixing under conditions providing a power per unit volume of 0 03 to 1 6 kW/m3
(c) separating the mixed metal compound from the slurry, to obtain a crude product having a dry solid content of at least 10 wt%
(d) drying the crude product either by
(i) heating the crude product to a temperature of no greater than 1500C and sufficient to provide a water evaporation rate of 0.05 to 1 5 kg water per hour per kg of dry product or
(ii) exposing the crude product to rapid drying at a water evaporation rate of
500 to 50000 kg water per hour per kg of dry product.
2 A method according to claim 1 wherein the compound is of the formula
Figure imgf000107_0001
mhfeO (II)
wherein M11 is one or more bivalent metals and is at least Mg2+;
M11' is one or more trivalent metals and is at least Fe3+;
An* is one or more n-va!ent anions and is at least CO3 2";
x/∑yn is from 1 to 1 2
0 < x≤ 0.4,
0 < y≤ 1 and
0 < m≤ 10.
3 A method according to claim 2 wherein x/∑yn is from 1 05 to 1 15 4. A method according to claim 2 wherein x/∑yn is 1 5 A method according to any one of the preceding claims wherein the moiar ratio of Mg2+ to Fe3Ms 2.5:1 to 1 5:1.
6 A method according to any one of the preceding claims wherein the compound has an average crystal size of from 10 to 20nm (100 to 200A).
7. A method according to any one of the preceding claims wherein the compound has an aluminium content of less than 100 ppm, 8 A method according to any one of the preceding claims wherein the compound has an aluminium content of less than 30 ppm
9 A method according to any one of the preceding claims wherein the total sulphate content of the compound is from 1 8 to 4 2 wt%.
10 A method according to any one of the preceding claims wherein the interlayer sulphate content of the compound is from 2 1 to 5 wt%
1 1. A method according to any one of the preceding claims wherein the interlayer sulphate content of the compound is from 2.2 to 5 wt%
12 A method according to any one of the preceding claims wherein the interlayer sulphate content of the compound is from 2 3 to 5 wt% 13 A method according to any one of the preceding claims wherein the interlayer sulphate content of the compound is from 2.5 to 5 wt%.
14. A method according to any one of the preceding claims wherein the pH of the slurry is maintained at from 9,5 to 10 5
15. A method according to any one of the preceding claims wherein the pH of the slurry is maintained at from 9 5 to less than 10.1.
16 A method according to any one of the preceding claims wherein the pH of the slurry is maintained at from 9,5 to less than 10. 17 A method according to any one of the preceding claims wherein the pH of the slurry is maintained at from 9 5 to 9 8
18 A method according to any one of the preceding cSaims wherein the Na2CO3 is provided at an excess of 2 0 to 4 0 moles than required to complete the reaction
19 A method according to any one of the preceding claims wherein step (a) comprises;
(A) combining a Mg2+ salt and a Fe3+ salt with Na2CO3 and NaOH to produce a slurry, wherein the slurry is maintained to a temperature between 15 and 30 0C, and-
(i) wherein the pH of the slurry is maintained at from 9.5 to less than 9 8, and wherein the Na2CO3 is provided at an excess of greater than 1 O to no greater than 5 O rnoies than is required to complete the reaction; or (ii) wherein the pH of the slurry is maintained at from 9 5 to less than 10, and wherein the Na2CO3 is provided at an excess of greater than 1 O to no greater than 4,0 moles than is required to complete the reaction; or (iii) wherein the pH of the slurry is maintained at from 9 5 to no greater than 10 1 , and wherein the Na2CO3 is provided at an excess of greater than 1 0 to no greater than 2.7 moles than is required to complete the reaction; or (iv) wherein the pH of the slurry is maintained at from 9 5 to 10 5, and wherein the Na2CO3 is provided at an excess of from greater than 1 0 to no greater than 2 0 moles than is required to complete the reaction; or (v) wherein the pH of the slurry is maintained at from greater than 9.5 to no greater than 11 , and wherein the Na2CO3 is provided at an excess of from 0 0 to no greater than 1 0 moles than is required to complete the reaction;
or step (a) comprises-
(B) combining a Mg2+ salt and a Fe3+ salt with Na2CO3 and NaOH to produce a slurry, wherein the slurry is maintained to a temperature from 30 to 60 0C, and-
(i) wherein the pH of the slurry is maintained at from greater than 9 5 to less than 11 , and wherein the Na2CO3 is provided at an excess of greater than O to less than 2 moles than is required to complete the reaction; or (iι) wherein the pH of the slurry is maintained at from greater than 9 5 to less than 10.5, and wherein the Na2CO3 is provided at an excess of greater than O to less than 2 7 moles than is required to complete the reaction; or (iii) wherein the pH of the slurry is maintained at from greater than 9.5 to less than 10, and wherein the Na2CO3 is provided at an excess of greater than 0 to less than 4 moles than is required to complete the reaction. 20, A method according to any one of the preceding claims wherein in step (b) the slurry is subjected to mixing under conditions providing a power per unit volume of 0.03 to 1.6kW/m3 while maintaining a slurry temperature of less than 650C
21 A method according to any one of the preceding claims wherein in step (b) the slurry conditions are controlled such that a d50 particle size distribution of at least 40 μm is provided.
22. A method according to any one of the preceding claims wherein in step (c) the mixed metal compound is separated from the slurry, to obtain a crude product having a dry solid content of at feast 15 wt%,
23. A method according to any one of the preceding claims wherein in step (c) the mixed metal compound is separated from the slurry, to obtain a crude product having a dry solid content of at least 20 wt%
24 A method according to any one of the preceding claims wherein in step (d) the crude product is dried by (i) heating the crude product to a temperature of no greater than 15O0C and sufficient to provide a water evaporation rate of 0,05 to 1 5 kg water per hour per kg of dry product.
25, A method according to claim 24 wherein in step (d) the crude product is dried by (i) heating the crude product to a temperature of no greater than 9O0C and sufficient to provide a water evaporation rate of 0.05 to 1 5 kg water per hour per kg of dry product. 26. A method according to any one of the preceding claims wherein in step (d) the crude product is dried by exposing the crude product to rapid drying at a water evaporation rate of 500 to 50000 kg water per hour per kg of dry product.
27. A method according to any one of the preceding claims wherein in step (d) the crude product is dried to a moisture content less than 15wt%, 28 A method according to any one of the preceding claims wherein in step (d) the crude product is dried to a moisture content less than 10 wt%.
29 A method according to any one of the preceding claims wherein the crude product is washed prior to step (d)
30 A method according to any one of the preceding claims wherein the mixed metal compound is separated from the slurry by centrifugation 31 , A method according to any one of the preceding claims wherein the dried crude product is milled ,
32, A method according to claim 31 wherein the dried crude product is milled to a d50 average particle size of less than 200 μm.
33 A method according to claim 31 wherein the dried crude product is milled to a d50 average particle size of less than 100 μm.
34. A method according to claim 31 wherein the dried crude product is milled to a d50 average particle size of 2 to 10 μm .
35 A method according to claim 31 wherein the dried crude product is milled to a d50 average particle size of approximately 5 μm. 36. A method according to any one of claims 31 to 35 wherein the milled dried crude product has a water content of 1 to 10 wt% based on the total weight of the dried crude product.
37. A method according to any one of the preceding claims for the production of a mixed metal compound having a lead content of less than 1 ppm.
38.. A method according to any one of the preceding claims for the production of a mixed metal compound having a chromium content of less than 30 ppm. 39. A method according to any one of the preceding claims for the production of a mixed metal compound having a totai heavy metal content of less than 10 ppm. 40 A method according to any one of the preceding claims for the production of a mixed metal compound having a sodium content expressed as Na2O of less than 0 5 wt% 41 A method according to any one of the preceding claims for the production of a mixed metal compound having a total heavy metal content of less than 15 ppm, a lead content less than 10 ppm, a chromium level less than 35 ppm and a sodium content (expressed as Na2θ) of less than 1 wt%. 42 A method according to any one of the preceding claims for the production of a mixed metal compound having a phosphate binding capacity of more than 0 6 mmol phosphate/g mixed metal compound
43 A method according to any one of the preceding claims for the production of a mixed metal compound having an average crystal size of less than 13nm (130A) and a phosphate binding capacity of more than 0 65 mmol phosphate/g mixed metal compound
44 A method according to any one of the preceding claims for the production of a mixed metal compound having an average crystal size of less than 9nm (9θA) and a phosphate binding capacity of more than OJO mmol phosphate/g mixed meta! compound
45. A method of producing a mixed metal compound comprising
at least Mg2+ and at least Fe3+
having an aluminium content of less than 10000 ppm,
having an average crystal size of less than 20nm (200A);
the method comprising the step of:
(a) combining a Mg2+ salt and a Fe3+ salt with NaaCO3 and NaOH to produce a slurry, wherein the slurry is maintained to a temperature between 15 and 30 0C, and:
(i) wherein the pH of the slurry is maintained at from 9 5 to less than 9 8, and wherein the NaaCO3 is provided at an excess of greater than 1 0 to no greater than 5 0 moles than is required to complete the reaction; or (ii) wherein the pH of the slurry is maintained at from 9.5 to less than 10, and wherein the Na2CO3 is provided at an excess of greater than 1 0 to no greater than 4 0 moles than is required to complete the reaction, or (iii) wherein the pH of the slurry is maintained at from 9 5 to no greater than 10 1 , and wherein the Na2CO3 is provided at an excess of greater than 1 0 to no greater than 2 7 moles than is required to complete the reaction; or (iv) wherein the pH of the slurry is maintained at from 9 5 to 10 5, and wherein the Na2CO3 is provided at an excess of from greater than 1 O to no greater than 2 O moles than is required to complete the reaction, or (v) wherein the pH of the slurry is maintained at from greater than 9 5 to no greater than 11 , and wherein the Na2CO3 is provided at an excess of from ϋ O to no greater than 1 O moles than is required to complete the reaction;
or the method comprising the step of
(b) combining a Mg2+ salt and a Fe3+ salt with Na^COa and NaOH to produce a slurry, wherein the slurry is maintained to a temperature from 30 to 60 0C1 and:
(i) wherein the pH of the slurry is maintained at from greater than 9 5 to less than 11 , and wherein the Na2CO3 is provided at an excess of greater than O to less than 2 moles than is required to complete the reaction; or
(it) wherein the pH of the slurry is maintained at from greater than 9 5 to less than 10 5, and wherein the Na2COa is provided at an excess of greater than O to less than 2 7 moles than is required to complete the reaction, or (iii) wherein the pH of the slurry is maintained at from greater than 9.5 to less than 10, and wherein the Na2CO3 is provided at an excess of greater than O to less than 4 moles than is required to complete the reaction.
46. A method according to claim 45, characterised by the features of any one of claims 2 to 44
47 A mixed rnetal compound obtained or obtainable by the method of any one of claims 1 to 46
48 A mixed metal compound comprising at least Mg2+ and at least Fe3+,
wherein
the molar ratio of Mg2+ to Fe3+ is 2 5 1 to 1 5:1 ,
the mixed metal compound has an aluminium content of less than 10000 ppm, the average crystal size of the mixed metal compound is from 10 to 20nm (100 to 200A), and the dδϋ average particle size of the mixed metal compound is less than 300 μm 49 A mixed metal compound according to claim 48 wherein the d50 average particle size of the mixed metal compound is !ess than 200 μm
50 A mixed metal compound comprising at ieast Mg2+ and at least Fe3+,
wherein
the molar ratio of Mg2+ to Fe3+ is 2 5.1 to 1 5.1 ,
the mixed metal compound has an aluminium content of less than 10000 ppm, the average crystal size of the mixed metal compound is from 10 to 20nm (100 to 200A)s and the water pore volume of the mixed metal compound is from 0 25 to 0 7 cm3/g of mixed metal compound
51. A mixed metal compound according to claim 50 wherein water pore volume of the mixed metal compound is from 0.3 to 0.65 cm3/g of mixed metal compound 52 A mixed metal compound according to claim 50 or 51 wherein the nitrogen pore volume of the mixed metai compound is from 0 28 to 0 56 cm3/g
53 A mixed metal compound comprising at least Mg2+ and at least Fe3+,
wherein
the molar ratio of Mg2* to Fe3÷ is 2.5.1 to 1 5.1 ,
the mixed metai compound has an aluminium content of less than 10000 ppm, the average crystal size of the mixed metal compound is from 10 to 20nm (100 to 200A)1 and the interlayer sulphate content of the compound is from 2 to 5 wt% 54 A mixed metal compound according to claim 53 wherein the average crystal size of the mixed metal compound is from 12 to 20nm (120 to 200A)
55 A mixed metal compound comprising at least Mg2+ and at least Fe3*,
wherein
the molar ratio of Mg2+ to Fe3+ is 2 5: 1 to 1 5:1 ,
the mixed metal compound has an aluminium content of less than 10000 ppm, the average crystal size of the mixed metal compound is less than 20nm (200A), and the interlayer sulphate content of the compound is from 2 1 to 5 wt% 56 A mixed metal compound according to claim 55 wherein the average crystal size of the mixed metal compound is from 10 to 20nm (100 to 200A).
57. A mixed metal compound according to any one of claims 48 to 56 wherein the interlayer sulphate content of the compound is from 2 2 to 5 wt%. 58. A mixed metal compound comprising at least Mg2+ and at least Fe3+,
wherein
the molar ratio of Mg2+ to Fe3+ is 2.5: 1 to 1.5-1 ,
the mixed metal compound has an aluminium content of less than 10000 ppm, the average crystal size of the mixed metal compound is less than 20nm (200A), and the surface area is from 80 to 145m2 per gram of compound,
59. A mixed metal compound according to claim 58 wherein the compound has a d50 average particle size of from 10 to 350 μm. 60. A mixed metal compound according to claim 58 or 59 wherein the compound has a d50 average particle size of from 10 to 100 μm
61 A mixed metal compound according to claim 58, 59 or 60 wherein the compound releases magnesium in an amount is less than 0,15 mmol magnesium/g compound
62. A mixed metal compound comprising at least Mg2+ and at least Fe3+,
wherein
the molar ratio of Mg2+ to Fe3+ is 2.5" 1 to 1 5 1 ,
the mixed metal compound has an aluminium content of less than 10000 ppm, the average crystal size of the mixed metal compound is from 10 to 20nm (100 to 200A), the surface area is from 40 to 80 m2 per gram of compound.
63. A mixed metal compound according to claim 62 wherein the water pore volume of the mixed metal compound is from 0 25 to 0.7 cm3/g of mixed metal compound
64 A compound according to any one of claims 48 to 63 wherein the compound is of the formula
Figure imgf000115_0001
wherein M" is one or more bivalent metals and is at least Mg2+;
M!" is one or more trivalent metals and is at least Fe3*;
Aπ" is one or more n-vaient anions and is at least CO3 2"; x/∑yn is from 1 to 1 2
0 < x < 0,4,
0 < y < 1 and
0 < m≤ 10.
65. A compound according to claim 64 wherein x/∑yn is from 1 05 to 1 15
66 A compound according to claims 64 wherein x/∑yn is 1.. 67. A compound according to any one of claims 48 to 66 wherein the compound has an aluminium content of less than 100 ppm
68, A compound according to any one of claims 48 to 67 wherein the compound has an aluminium content of less than 30 ppm.
69, A compound according to any one of claims 48 to 68 wherein the interlayer sulphate content of the compound is from 2 to 5 wt%.
70. A compound according to any one of claims 48 to 69 wherein the compound has a d50 average particle size of less than 100 μm.
71. A compound according to any one of claims 48 to 70 wherein the compound has a d50 average particle size of 5 to 50μm. 72. A compound according to any one of claims 48 to 71 wherein the compound has a d50 average particle size of approximately 5 μm.
73. A compound according to any one of claims 48 to 72 wherein the water pore volume of the mixed metal compound is from 0 25 to 0.7 cm3/g of mixed metal compound.
74. A compound according to any one of claims 48 to 73 wherein the compound has a dry solid content of at least 20 wt%
75. A mixed meta! compound according to any one of claims 47 to 74 for use as a medicament.
76. A mixed metal compound according to any one of claims 47 to 74 for binding phosphate.
77. A mixed metal compound according to any one of claims 47 to 74 for use in the treatment of hyperphosphataemia,
78. A pharmaceutical composition comprising a mixed metal compound as defined in any one of claims 47 to 74 and optionally one or more pharmaceutically acceptable adjuvants, excipients, diluents or carriers
79 A pharmaceutical composition according to claim 78 in the form of a tablet, capsule or granule.
80, A method as substantially described herein with reference to the examples.
81 , A mixed metai compound as substantially described herein with reference to the examples
82, A pharmaceutical composition as substantially described herein with reference to the examples.
PCT/GB2010/051271 2009-08-03 2010-08-02 Method WO2011015859A1 (en)

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EP19186506.2A EP3611131A1 (en) 2009-08-03 2010-08-02 Magnesium-iron layered double hydroxides, their manufacture and their use for treatment of hyperphosphataemia
ES10739987T ES2751325T3 (en) 2009-08-03 2010-08-02 Double hydroxides with magnesium-iron layers, their production and use for the treatment of hyperphosphatemia
US13/388,476 US9314481B2 (en) 2009-08-03 2010-08-02 Method
EP10739987.5A EP2462062B1 (en) 2009-08-03 2010-08-02 Magnesium-iron layered double hydroxides, their manufacture and their use for treatment of hyperphosphataemia
DK10739987.5T DK2462062T3 (en) 2009-08-03 2010-08-02 Layered DOUBLE HYDROXIDES OF MAGNESIUM IRON, MANUFACTURING IT AND USING IT TO TREAT HYPERPHOSPHATATY
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US14/224,040 US9066917B2 (en) 2009-08-03 2014-03-24 Mixed metal compound
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